FOR INTERNAL CIRCULATION ONLY

DOC. NO. D-2-02-70-02-00 (REVISION-0)

ERECTION MANUAL OF
EMERGENCY RESTORATION SYSTEM
(DISASTER MANAGEMENT)


























CORPORATE OPERATION SERVICES
POWERGRID CORPORATION OF INDIA LIMITED
(A Government of India Enterprise)
NEW DELHI 110 019




INDEX

SL.
NO.
CONTENTS

PAGE

1.0 INTRODUCTION 1
2.0 DISASTER MANAGEMENT STRATEGY 3
3.0 COMPONENTS OF STRUCTURES 4
4.0 TYPES OF ASSEMBLED STRUCTURES 10
5.0 SITE PLANNING AND SURVEY 12
6.0 FAILURE AND RESTORATION SCENARIOS 14
7.0 TRANSPORTATION ARRANGEMENT 22
8.0 COMPUTER PLANNING 24

ERECTION OF ERS

9.0 EXCAVATION OF PITS 32
10.0 GUY ANCHORING 33
11.0 GENERAL ASSEMBLY AND ERECTION
INSTRUCTIONS FOR THE STRUCTURE
35
12.0 ERECTION PROCEDURE USING A GIN POLE 45
13.0 ERECTION PROCEDURE USING A BOOM-
TRUCK OR LIGHT DUTY CRANE
51
14.0 ERECTION TECHNIQUE INVOLVING TILTING UP
OR WHIPPING UP THE ERS COLUMN WITH A
WINCH LINE
54
15.0 SPECIALISED ERECTION PROCEDURE USING A
HELICOPTER
56

SL.
NO.
CONTENTS

PAGE

16.0 CLIPPING-IN PROCEDURES 64
17.0 DISASSEMBLY OF ERS 70
18.0 PACKING AND STORING OF ERS 71
19.0 MAINTENANCE OF ERS 72
20.0 SAFETY GUIDELINES DOS AND DONTS 73
21.0 TROUBLE SHOOTING 75
22.0 ANNEXURE I: BILL OF ERS MATERIALS IN
ONE SET
77

ANNEXURE II: LIST OF ADDITIONAL TOOLS
AND PLANTS
83
ANNEXURE III: DETAILED GUIDELINES FOR
TRANSPORTATION OF ERS
STRUCTURE IN TRUCKS OF 18
FEET LONG BODY
85
ANNEXURE IV: SAMPLE ERS COMPUTER
PRINT-OUTS
89
ANNEXURE V: DEMONSTRATION OF
ERECTION OF COMPLETE ERS
TOWER BY HELICOPTER
101
ANNEXURE VI : IMPORTANT EXAMPLES OF USE
OF ERS AT CRITICAL
LOCATIONS (220 KV D/C
BAIRASUL-PONG LINE AT
TOWER LOCATION NO. 59)
109
23.0 REFERENCES 118
























1.0 INTRODUCTION
1.0 INTRODUCTION

For disaster management in case of natural calamities and sabotage, the
Emergency Restoration System (ERS) which is used world wide was
adopted by POWERGRID to enable quick restoration of Power Supply
by erecting the ERS and by-passing the damaged portion of Transmission
Lines.

Its application is effective and is economically viable specially for Power
Systems where redundancies of transmission system are lacking. The
ERS structures require no special foundation and can be used at any
voltage level. There are various chapters, each covering step-wise
procedure for restoration work along with safety guidelines, trouble
shooting and illustrations/ demonstrations.

The ERS consists of number of standardised modular, high strength, light
weight aluminium alloy components/ blocks which can be easily and
quickly erected to form a full scale guyed tower at an alternate location
near the affected towers. With these components, 15 type of structures of
Suspension and Tension/Angle type can be assembled suiting to specific
need based on site details and computer planning. With suitable Design
and Computer Planning, ERS can also be effectively used to By-pass
damaged special tall towers and special pile/ well foundations. Efforts
have been made to illustrate typical failure scenarios and also their
restoration scenarios so that site people can adopt the restoration
scenarios suiting to them for quick restoration.

This document contains some general guidelines/ suggestions and
recommended practices which, should be followed when using
Emergency Restoration Structures mainly of the type covered in this
manual only. In order to maximise the potential benefit which can be
derived from using these structures in an emergency situation, it is
essential that sufficient computer planning and site training has been
accomplished prior to the occurrence of an emergency.

In the procedure for assembly and erection of the ERS, detailed method
of work has been mentioned for different types of erection procedures.
The complete tower is erected on a nailed base foundation plate. The
Gimbal Joint arrangement pivoted with the foundation bearing base plate
minimises the column eccentricity and eliminates torsional loading due to
its rotational capability in various directions. All column section are simply
assembled and the ERS structure is erected with the support of guy wires
that are attached to the guy plates using anchors, shackles and
preformed grips. Light weight high dielectric strength polymer suspension
insulators/ post insulator strings are used for re-stringing of the existing
line conductors or new conductor. With the completion of above
operations, the line is ready for restoration. The most commonly used
erection procedure is by using Gin Pole. However, this is time consuming
and restoration depends on number of technicians/engineers deployed for
the work. In case of emergency, boom truck/light duty crane had been
used and based on the experience gained, procedure has been outlined
in the document. It was also thought to acquire expertise in erection of
ERS with the help of helicopter in case of extreme emergency and in
unapproachable areas. The procedure for helicopter erection has also
been given. Based on the demonstrations, erection of complete
assembled ERS tower in one step has been illustrated at Annexure-VI of
this document.

As with any other piece of equipment or tool, all normal safety
precautions should be followed when working on or around these
structures. Care should be taken to ensure that the structures are not
handled or used in a manner which may cause damage. Any and all
national, state or local safety requirements need to be observed at all
times. Safety guidelines (DOs and DONTs), trouble shooting,
Packing/storage and maintenance of ERS have also been covered. In the
last list of ERS materials, Tools & Plants required for construction and
guidelines for transportation in the trucks have been given alongwith the
sample ERS computer print-outs and the important example of use of
ERS.

The successful application of ERS for the first time is a step ahead in
POWERGRIDs march for excellence in finding innovative solutions and
state of the art technology in the field of extra high voltage transmission
maintenance technology and disaster management in the country.























2.0 DISASTER MANAGEMENT STRATEGY
2.0 DISASTER MANAGEMENT STRATEGY

Failure of transmission line towers due to natural calamities and sabotage
cannot be ruled out. However, to tackle the situation arising out of these
factors, we should be able to manage the disaster as quickly as possible
so that power supply can be maintained to the consumers. As a strategy
to disaster management, one of the State-of-Art technique is to deploy
Emergency Restoration System for restoration of collapsed towers. This
technique is also used to by-pass critical/damaged towers and
foundations.

POWERGRID have following sets of ERS at different locations to manage
the disaster through out the India.

Region

Location Quantity
NR-I Ballabhgarh
Kanpur
1 set
1 set
NR-II Jammu / Hissar/ Wagoora 1 set
WR Dehgam (Ahmedabad)
Itarsi
1 set
1 set
SR Vijayawada/ Vaizac
Bangalore
1 set
1 set
ER Durgapur
Rourkela
1 set
1 set
NER Misa 1 set
T O T A L 10 SETS

Each set consist of various components which have been mentioned in
next chapter number 3. Further, each set is capable of erecting 12 nos. of
ERS towers upto 400kV (twin conductors) of different types as indicated
in chapter number 4. Moreover, in an emergency situation the ERS and
the man power is pooled from various locations so that the entire damage
can be tackled effectively. POWERGRID have also developed expertise
for transportation and erection of ERS using helicopters. In a situation
where requirement of power is extreme, helicopters can be deployed for
erection of ERS as per procedure given in chapter no.15.




















3.0 COMPONENTS OF STRUCTURES
3.0 COMPONENTS OF STRUCTURES

3.1 FOUNDATION PLATE


This is designed for placement (Fig-1) directly on the flat/ slope (40
0
max.)
ground. The plate weighs 250 kg and provides 2.32 square meter of bearing
surface and can be pinned to normal ground (dry soil) using 25 mm diameter
reinforcing rods approximately 1.5 meter long. In case of loose soil,
foundation plate can be placed on the 4 numbers screw/marsh anchors
driven in the ground to increase the bearing strength of the soil. The height of
the foundation plate is 0.36 meter. Normally four numbers of reinforcing rods
are to be used to secure the foundation when the column is erected.
Foundation secured in this manner can also be remained in service for long
time.

Figure-1

3.2 GIMBAL JOINTS

The first section above the foundation plate is the Gimbal Joint (Fig-2) which
can rotate 90
0
in four major axis (in four directions) as indicated by arrow
attached on the Gimbal allowing horizontal column assembly. Above the
Gimbal, the required column sections can be bolted together. Once the
Gimbal Joint is assembled with column section horizontally, the cranes/ winch
line/ helicopter can be used to lift the column into position using the Gimbal
Joint as a pivot. The Gimbal Joint can be locked rigid for initial erection,
storage, handling and for transportation with the help of turn-buckles. The
Gimbal weighs only 252 kg. The length of Gimbal Joint is 2.13 meter (7 feet).

Figure 2

3.3 COLUMN SECTIONS
Figure-3

All column sections (Fig-3) are made of light weigh, high strength structural
aluminium alloy. The column section ensures easy handling and eliminates
the loss of small bolted pieces such as diagonal bracing etc in view of welded
bracing. The column sections are in three standard sizes 2.13(7 feet), 4.26
(14 feet), 6.4(21 feet) meter long weighing 123, 189, and 256 kg respectively.
Locating pins and alignment holes are provided in each flanged end plate for
a easy assembly and erection.

3.4 GUY PLATES

Figure-4

The guy plates are made from structural aluminium plate. Guy plates weigh
23 kg and are available in three types (Fig-4), 0
0
- 45
0
is used for guying and
full tension dead end structures; 45
0
- 45
0
guy plate is used for suspension
structures, intermediate guying is the most commonly used guy plate for
anchoring and 0
0
- 0
0
guy plate is used for In-line tension structures. Each of
the six guy plate attachment holes are rated for ultimate load of 134 kN. Guy
plates assembled between two column sections is used for intermediate
guying. Guy wires are typically attached to the guy plates using anchor
shackles and preformed grips.

3.5 BOX SECTION

Box section (Fig-5) is made from structural aluminium and used for mounting
horizontal post insulators. Box section weigh 120 kg and are installed in-
between column sections and have pre-drilled holes on two sides to allow
mounting of any line post insulator. It is used for mounting post insulator in H-
Frame, Horizontal Vee and Delta Horizontal Vee type of structure geometry.
In addition to this, box sections are used on tension towers for connecting
jumper through line post insulators.


Figure-5

3.6 INSULATORS AND HARDWARE

The suspension and post polymer insulators (Fig-6) are used on account of
their high strength, lightweight and durability. Hardware components are
provided for greatest number of assemblies with the least number of
components. The advantages of polymer insulators is that, a lineman can
carry easily due to lightweight i.e. 10 kg. for suspension insulators and 27 kg
for post insulator suitable for use up to 400 kV line.



Figure-6
3.7 ANCHORING SYSTEM

Anchoring System (Fig-7) is a critical element of the guyed ERS. Depending
on the prevailing soil conditions, a number of different anchoring
arrangements can be provided. Cross plate anchor for normal soil(dry) is the
most common and universal anchoring method that require minimal
installation equipment. In most cases, cross plate anchoring (Fig-8) is the
quickest and easiest type of anchoring. Screw anchors for loose soil and
Rock-anchoring system for hard rock can also be used to meet specific
requirements. Dead weigh anchoring is used where other anchoring will not
work. In case of heavy dead weight made of concrete blocks are not
available, locally fabricated crate made of steel angles filled with sand bags/
stones can be used.

3.8 GIN POLE (DERRICK)

Gin pole is basic tool for erection of ERS modular structures by putting one
above another. The length of Gin pole is 7.3 meter which can erect ERS
structures even up to 50 meter tall.

3.9 6 TON CHAIN HOIST

This is used to connect guy wire with the anchor rod. With the help of chain
hoist, the guy wire can be loosened and tightened. After proper tension in guy
wire, chain hoist can be removed and guy wire is clamped with the anchor rod
using preformed Armour grips.

3.10 PRE-FORMED ARMOUR GRIPS

This is used to finally clamp, one end of guy wire with the Anchor rod and
other end of the guy wire with the guy plate. This Pre-formed armour grips
are consumable and shall not be used after 2-3 applications.

3.11 OTHER ACCESSORIES

There are other accessories/ hardware alongwith each set of ERS. The list is
given in Annexure-I.














4.0 TYPE OF ASSEMBLED STRUCTURES



4.0 TYPE OF ASSEMBLED STRUCTURES

When we assemble components of structures supplied with each ERS set, it
results into 15 types of structures as given in figure number 9. These are
mainly Tangent structures, Angle structures and Dead end structures. Seven
types of Tangent structures, four types of Angle structures and four types of
Dead end structures can be assembled. The most commonly used structures
with 400kV are Horizontal Vee (Suspension and Angle type), Snubbing and
In-line angle structures. Single phase or two phases or three phases can be
taken on Dead end structures depending upon length and tension of the
span.

Though Horizontal Vee is tangent structure as well as angle structure but it
cannot be used at 0 degree line deviation. Small angle around five degree
should always be provided so as to increase stability and strength of tangent
type Horizontal Vee structure.

In-line Dead end structures are most suitable for longer spans such as river
and valley crossing.

Before using any of these structures, it is essential that proper site planning
and survey is carried out based on route of the line as given in next chapter
number 5.



Figure-9














5.0 SITE PLANNING AND SURVEY

5.0 SITE PLANNING AND SURVEY


Survey the site and study the technical feasibility for installation of various
types of ERS structure (Figure-9). One of the main criteria for locating the
towers is to maintain electrical clearance from the existing transmission
line and from the ground. Procedure for survey is given below :

PROCEDURE FOR SURVEY:-

Visit tower location(s) which are required for bypassing circuit through
ERS.
See availability of space required for ERS structure and guy, depend on
type of failure.
Choose the location for Foundation plate (base) and the anchoring point.
Measure the angle of ERS structure and span(s)
Decide on type of structure
6. Following T&P shall be required for carrying out the above survey work.


S. No. Name of T&P Quantity

1. Theodolite As per site
requirement
2. Chains

3. Arrows/ Marking Pins/ Steel Marker

4. Dumpy Level

5. Tripod stand

6. Wooden pegs

7. Ranging rod/ Nail/ Spikes

8. Offset rods

9. Plumb bob

10. Tape (Cloth or linen tape/ Metallic)

11. Shoulder pad

12. Field Book

13. Cross staff/ Optical square




Co-ordinate with local administration, forest authorities, Railway
authorities for railway crossing, power utilities for power crossing and also
make boarding & lodging arrangement of crew members at site.

Based on site planning and survey, there may be possibility of restoring
the line using different restoration scenarios. Each restoration scenario
has certain advantages and its application depends on site conditions.















6.0 FAILURE AND RESTORATION SCENARIOS


6.0 FAILURE AND RESTORATION SCENARIOS

Restoration of collapsed towers depends on type of failures. This is in
view of the fact that many types of tower design have been used in
different wind zones. While restoring the collapsed towers with the help of
ERS structure the strength and capability of first and last permanent tower
which would support ERS columns has to be kept in mind. This calls for
various failure and restoration scenarios which is specific to each site.
Following are the examples based on the experience along with their
merits and de-merits.

6.1 SCENARIO NO. 1

In case the failed tower is suspension or tension type but the adjacent
intact towers are tension type. There are 3 possibilities of restoring the
collapsed tower which is shown in Figure 10 and 11. Normally, option 1 is
most suitable with least no. of towers as the adjacent intact towers are of
tension type. Other options may be necessitated only in view of site
constraints but with advantage of reduced shut down period for
permanent restoration.














6.2 SCENARIO NO. 2

In this scenario failure of more than one suspension tower and their
restoration have been shown keeping the adjacent tower as tension
towers only. This case is similar to scenario no. 1 except no. of ERS
structures required will depend on no. of permanent towers collapsed and
condition of the site (Figure 12 and 13).


















6.3 SCENARIO NO. 3

On one side intact tower is tension type and on the other side the intact
tower is suspension type. In this case the first ERS tower & intact
suspension tower should be almost in line of the existing route conductor.
This is required as large angle cannot be allowed on suspension tower.
However, by reducing span & tension the angle on intact suspension
tower may be slightly increased as per tower design. On the other side
intact tension tower, the angle of line conductor can be very close to
capability of the tower or may be slightly higher in case span is slacked
and reduced as per tower design ( tower spotting data).(Figure 14 and
15)




6.4 SCENARIO NO. 4

Both sides of collapsed towers are the suspension type of towers. In this
case the options 1 or 2 given in tower failure scenario no. 3 may be
followed. However, small or large angle as shown for suspension towers
have to be maintained both sides of intact towers.

6.5 SCENARIO NO. 5

This scenario is applicable for by-passing critical towers on the bank of
Rivers. In this case given option is considered by using the dead-end in
line structures of ERS. This can take longer span by providing
intermediate guys to enhance the capability of the ERS structures.

In all the above, scenarios, only single circuit restoration has been shown
which is normally sufficient in emergency. However, if double circuit
restoration is required, the same can be done by following similar
procedure on another side of failed line.

On finalising the restoration scenario, i.e. route of erection of ERS towers,
tentative bill of materials required at site can be prepared for
transportation. Bill of materials available in each set of ERS is given in
Annexure-I. Now the Material can be transported to the erection site.
















7.0 TRANSPORTATION ARRANGEMENT




7.0 TRANSPORTATION ARRANGEMENT

After tower failure, a team has to visit site to look into the feasibility of
location of ERS installation. Then number of towers to be By-passed on
ERS are to be identified along with the type of structure (geometry).
Subsequently the anchoring location and number of anchoring point has
to be decided.

However, after finalisation of Restoration scenario, mode of
transportation can be decided, depending upon the location of stores
where ERS components and T&P are stored.

Different mode of transportation that can be adopted are as follows:-

7.1 BY ROADS

Broadly there are two type of road transportation that are undertaken:-

By Trailer

ERS container containing all ERS components are loaded on Trailer.
The Container has been designed in such a way that during
transportation, no damage occurs. For Trailer, its availability and
suitability of road condition is important.

By Truck

In case a Trailer is not available, else trailer is available but road
condition to the erection site of ERS is not suitable then it can be
transported by trucks also which are readily available and are
comparatively cheaper. Depending upon the requirement more no. of
truck can be used. With the help of trucks, ERS materials can be
delivered to the nearest possible location of ERS erection site. From
there onwards, it can be transported by head loading with the help of
labourers to work site.



7.2 BY AIR

In case of hilly terrain, snow bound area and flooded area where
transportation by above modes is difficult, ERS can be transported to
nearest erection site from store by Air. In such case, erection can also be
done by a helicopter. As helicopter usage is more expensive as
compared to conventional method, but very fast, the same can be
deployed in urgent situation like backing down the generation and for
avoiding insurmountable suffering of public at large . Also in case of flood/
storm, if the roads are damaged and there is no other possibility to
transport material/ man then helicopter can be used. Further more if the
location is on the top of the hill or the location is not easily approachable
then also helicopter can be used. By helicopter, ERS erection gang can
also be transported if required. However again the availability of
helicopter and the distance from Airport to ERS store is to be looked into
along with the clear area to enable the helicopter to land. In such case,
the clearance from the local authorities is to be obtained. If the distance is
more, then the helicopter has to stop in between stations for refuelling
which has to be kept in mind.

Detailed guidelines for transportation of ERS structure in trucks of 18 feet
long body are given in Annexure-III.

While transportation is in progress, computer planning for each ERS tower
can be taken up.
















8.0 COMPUTER PLANNING



8.0 COMPUTER PLANNING

Computer analysis programs are a critical part of the Modular Emergency
Restoration System. Registered copy of the complete set of computer
programs is available with each regional head quarter/ site office of
Powergrid. A copy of floppy containing ERS Program has been provided
in the pocket of the folder.

8.1 THE PROGRAM :

The program is on a single 3 HD floppy disk. The program is DOS
based, although it can also be run in a DOS Window. The program can
be run from the floppy or, if desired, it can be copied to the hard drive for
faster operation. If copying to the hard drive, create a separate directory,
such as ERS, and copy the entire contents of the floppy disk to that
directory on the hard drive.

The following programs are contained on the disk :
ATCHAIN.EXE
AT4POLE.EXE
ATHVEE.EXE
DEADEND.EXE
MENU1.EXE
ERS.EXE
BRUN30.EXE
HVEEDC.EXE
DELTAHV.EXE
HBONESC.EXE
HFRAME.EXE
PCRIT.EXE
MENU2.EXE
BRUN30.EXE

Each program is compiled and in executable format. BRUN30.EXE is a
copyrighted product of Microsoft that enables the compiled programs to
run.

8.2 SYSTEM REQUIREMENTS :

The programs are designed to run on most any IBM or compatible
personal computer. There are no special features, such as graphics, in
order to keep the programs as universally usable as possible. The
minimum system requirements are :

IBM PC/XT/AT or compatible computer
256K RAM
One 3-1/2, double sided, double density (360K) disk drive
Display Monitor (Graphics capability not required)
MS-DOS or PC-DOS 2.1 or higher

A hard disk drive in recommended since the programs will operate
quicker. Approximately 500K is required to store the programs.

8.3 OPERATION :
To run the program, type ERS. A menu showing the various types of
structures analysed by the programs is displayed.

Selecting Units: To select the desired units, go to the Utilities option
from the main menu. Select either E for English units or M for metric
units. The program will ask whether to reset the data files. On the initial
time through, select Y, yes. If you go through utilities again later,
selecting Y to reset will erase any saved information.

Example: From the main menu screen, select C to analyze a Chainette
structure. This takes you to the main chainette menu. The information
required to analyze a Chainette, or any structure type, is broken down into
Conductor/OHGW information, Loading information, Span/Conductor
Height information and Geometry/Guying information.

Selecting any of these categories will allow you to view and edit the
information. The program saves the most recent information as Default.
It is possible to save up to 20 data sets for each type of information. The
Geometry information is used only with the Chainette program; however,
the other three categories are common to all of the structures.

The E, edit, option in each of the information categories gives a more
detailed explanation of the desired information, including sketches and
worksheets to assist you in entering the correct information.

Once all of the information has been entered, selecting A, analyze, will
have the program evaluate the Chainette structure based on the
information that you have provided. If a G, general solution, has been
selected in the Span/Conductor Height information category, the program
will display a simple graph of allowable conductor height versus span. If
the guy loads or insulator loads exceed the pull-out strength of the guy
plates, the graph will reflect this information. Selecting S, specific,
enable you to enter a specific height and span and receive a more
detailed analysis, with the option of printing the results (sample attached).
Selecting S specific, from the Span/Conductor Height information
category skips the general graph and goes directly to the specific solution.

8.4 STRUCTURAL ANALYSIS COMPUTER PROGRAMS

This manual explains how to analyze the Modular Emergency Restoration
structures, including the general analysis theory as well as information on
the operation of the enclosed computer programs.

It is highly recommended that a copy of the original disks be made and
the original disks stored in a safe location. The programs can either be
run from the floppy disks or from a hard disk drive.

For analysing the structure on computer, following definitions shall be
used.
8.5 DEFINITIONS
Additional Assumed Eccentricity (in): Typical value of e3 eccentricity
for additional column eccentricity range from 0 to 6 inches.

Conductor Diameter (in): The bare sub-conductor diameter, in inches.
For example 795mcm ACSR Drake conductor has a diameter of 1.108
inches.

Conductor Weight Per Foot (lbs/ft) : The bare sub-conductor weight per
unit length, in pounds per foot. For example 795mcm ACSR Drake has a
weight of 1.094 lbs/ft.
Conductor Tension (lbs): The sub-conductor tension, in pounds, including
any effect of ice and wind that might increase the tension but excluding
the line tension overload factor. Typical values are 15 to 25 percent of the
ultimate strength of the sub-conductor. This value is not requested in
programs that are used as tangents only.

Horizontal Overload Factor (Ratio): The overload capacity factor applied
to transverse loads caused by wind. In the National Electric Safety Code
(NESC), Table 261-2, the horizontal overload factor is 2.50. For extreme
wind conditions a horizontal overload factor of 1.0 can be used.

Initial Guy Tension (lbs): The initial construction tension of the guy wires
prior to raising the conductors, given in pounds. Typical values are 500
to 1000 pounds.

Line Tension Overload Factor (Ratio): The overload capacity factor
applied to line tension loads. In NESC, Table 261-2, the line tension
overload factor is 1.65. For extreme wind conditions a line tension
overload factor of 1.0 can be used. This value is not requested in
programs that are used as tangents only.

Maximum Vertical or Compressive Load (lbs): For a given set of
conditions (i.e. weight span, tower height, etc.), the resulting compressive
load on the foundation, in pounds. Dividing the value by the area of the
foundation, 25 ft2, gives the soil bearing pressure under the foundation in
lb/ft2.

NESC: National Electrical Safety Code. The minimum general loading
requirements (i.e. wind and ice) and strength requirements (i.e. overload
factors) that a permanent transmission structure in the United States
should withstand.

Number of Conductors Per Phase : The number of sub-conductor per
phase, typically 1,2,3 or 4. For example, the input value for a triple bundle
conductor arrangement per phase would be 3.

OHGW (Overhead ground wire): Also referred to as the shield wire,
static wire, lightning wire, etc.

OHGW Diameter (in): The bare overhead ground wire diameter in inches.

OHGW Weight per Foot (lbs/ ft): The bare overhead ground wire weight
per unit length in pounds per foot for values of commonly used stranded
steel cable.

OHGW Tension (lbs): The overhead ground wire tension, in pounds,
including any effect of ice and wind that might increase the tension but
excluding the line tension overload factor. Typical values are 15 to 25
percent of the ultimate strength of the OHGW. This value is not requested
in programs that are used as tangents only.

Post Insulator Angle from Horizontal (deg) : The upward slope of the
post insulator when mounted on a vertical surface. Post insulators
typically used with ERS have angles between 0 and 15 degrees.

Post Insulator Buckling Load (lbs): The ultimate compressive strength
of the post insulator, in pounds. This value is used to determine the
maximum span that the post insulator can hold. For insulators with a 2.5
inch fibreglass rod, commonly used with ERS, values range from 20,000
lbs for an 8 foot length to 10,000 lbs for a 10 foot length.

Post Insulator Length (ft): The projected horizontal length of a horizontal
post insulator measured from its base to conductor attachment point,
given in feet.

Radial Ice Loading (in): The radial thickness of ice applied to each sub-
conductor and OHGW in inches. The ice is assumed to have a density of
57 lb/ft
3
.

Ratio of Wind to Weight Span (wd/wt): The ratio obtained by dividing
the wind span by the weight span. The wind span, or horizontal span, is
defined as one half the sum of the conductor spans on either side of the
structure. The weight span, or vertical span, is defined as the sum of the
distances from each side of the structure to the low point of the conductor
catenary curve. The program calculate loads based on weight span only,
and use this ratio to adjust the values for the wind span. On level terrain
this ratio is 1.0. For a structure on top of a hill, the ratio would be less
than one. For a structure in a valley, the ratio would be greater than one.

Shape Factor for Column Wind Load (Ratio): The drag ratio of a non-
cylindrical surface to a cylindrical surface for the same wind pressure. In
NESC, Section 252B(2)(c), the minimum factor for a square latticed
structure is 3.2.

Total Line Angle (degrees): The total angle, in degrees, that the
conductors turn at the structure when projected onto the horizontal plane.

Vertical Overload Factor (Ratio): The overload capacity factor applied to
the weight of the conductor and ice. In NESC, Table 261-2, the vertical
overload factor is 1.50. For extreme wind conditions a vertical overload
factor of 1.0 can be used.

Vertical Phase Separation (ft): The vertical separation of phases,
measured in feet. For the Horizontal Vee and Delta Horizontal Vee
structures, as well as Deadend structures that utilize a post insulator
jumper, this separation is a box section height (1.5 feet) plus a standard
column section height (7,14, or 21 feet). For the Herringbone structure
and Deadend structures that do not utilize a post insulator jumper, this
separation is a standard column section height (7,14 or 21 feet).

Weight Span (ft): The sum of the distances from each side of the
structure to the low point of the conductor catenary curve. The weight
span is multiplied by the Ratio of Wind to Weight Span to give the
corresponding wind span. This span is also commonly referred to as the
vertical span.

Conductor Wind Load, without Overload (lbs/sq ft): The wind pressure
on the projected area of the conductors and OHGW, excluding the
horizontal overload factor, given in pounds per square foot. The program
will automatically add the radial ice to the conductors and OHGW and
calculate the projected area. This area is multiplied by the wind pressure
and by the horizontal overload factor.

Column Wind Load, with Overload (lbs/sq ft) : The wind pressure on
the projected area of the ERS column, including the appropriate horizontal
overload factor. The program multiplies the column wind load by the
shape factor and the projected area, but does not multiply the wind
pressure on the column by the horizontal overload factor.

X-Vertical Slope of Guy Wire (X to 1): The vertical change in the guy
wire for a unit horizontal change. X is the rise of the guy for a run of 1.
Refer to drawings of each ERS type in computer programme for a specific
definition of the X-slope for that structure.

Y-Horizontal Slope of Guy Wire (Y to 1): The spread of multiple guys in
the plan view. Refer to drawings of each ERS type in computer
programme for a specific definition of Y-slope for that structure.

8.6 INPUT DATA FOR COMPUTER PROGRAMS

There is no standard formula that can be identified for ERS installation.
However computer analysis programs has to be used prior to finalising
for Emergency Restoration Structures. These user-friendly programs
allow the utility engineer to quickly analyse any of the Emergency
Restoration Structures configuration. User may use laptop computer for
field analysis for different Emergency Restoration Structure
configuration. Following input data are required to analyse the structure.
8.6.1 Input Data

a. Conductor/ OHGW Data



Quantity per phase
Diameter
Unit weight
Everyday Tension
Maximum Tension
Units

no.
cm
kg/m
kN
kN
Conductor OHGW

---

b. Wind/ Ice/ OLF Loading Data



Wind on Conductor
Wind on Column
Radial Ice (thickness)
Conductor/ OHGW
Tension
Shape Factor
Vertical Overload
Horizontal Overload
Line Tension Overload
Additional Eccentricity
Units

Pascal
Pascal
cm






cm




(E-Everyday, M-Maximum)

c. Line Profile/ Span / Height Data



Total Line Angle
Span Information Type
Wind Span
Weight Span
Ratio of Wind Span to weight
Span
Desired Conductor Height
Units

Degrees

meters
meters


meters


General/ Specific

d. Structure Geometry/ Guying Data

Input data are different and depend on the type of structure. The
input data are to be taken from concerned line design parameters
and as given for ERS structure and also in computer floppy.

8.6.2 Output Data

After all the data have been fed in the programme, it will give the output
regarding suitability of structure. The output data will include the
following information:

* Allowable conductor height and span
* Insulator loads
* Guy and anchor loads
* Intermediate guy wire requirements
* Right-of-way requirements

Sample computer planning have been carried out for each type of
structure for guidance of users.


8.7 SAMPLE PRINT-OUTS :

Attached are sample print-outs (Annexure IV) of the various structure
types that can be analyzed, including the Horizontal Vee, Delta Horizontal
Vee, Deadend, Running Angle(Single Phase), Running Angle(Three
Phase), Chainette, 4 Column, Single Circuit Herringbone and Double
Circuit Herringbone. Also included are print-outs from the P-Critical
column analysis program, the various column Erection Analysis options
and the Wind/ Weight Span Circulation Worksheet.

The above input/ output data and computer print out can be converted
between metric and English units of measure.

8.8 CONVERSION FACTORS

The following factors are for soft converting between Metric and English
units of measure.

Length:
1mm = 0.0396 in
1 m = 3.2808 ft
1 km = 0.6214 mile

1 in = 25.40 mm
1 ft = 0.3048 m
1 mile = 1.609 km
Area :
1 m
2
= 10.76 ft
2

1 cm
2
= 0.155 in
2


1 ft
2
= 0.0929 m
2

1 in
2
= 6.452 cm
2

Mass :
1 kg = 2.2046 lb

1 lb = 0.4536 kg
Force :
1 kN = 224.82 lb

1 lb = 0.00445 kN
Pressure
1 Pa = 1 N/m
2
= 0.020886 lb/ft
2


1 lb/ft
2
= 47.879 Pa

Wind Speed to Pressure :
1 lb/ft
2
= 0.00256*(mph)
2


1 lb/ft
2
= 0.0129*(m/s)
2

Other:
1 kg/m = 0.672 lb/ft
1 km/h = 0.6214 mph

1 lb/ft = 1.488 kg/m
1 mph = 1.609 km/h














9.0 EXCAVATION OF PITS

9.0 EXCAVATION OF PITS

The first step of erection of ERS is excavation. The procedure and T&P
required is given below.

Procedure:-

1. Dig hole of 1 meter X 1 meter square area and 2-3 meter deep
depending on soil.
2. In case of rock drill by drilling machine.
3. In case of anchoring in loose soil, screw marsh anchors are to be
driven up to refusal level (minimum 2-3 meter)
4. A hole or a cut at 45 degree is to be made for inserting anchors rod
from top to bottom of pit.
5. The size of pit i.e. length & width should be as small as possible so
that soil is not much disturbed.
6. In case water level is high, additional pits shall be made to share the
load on anchors.

Tools & Plants

S. N Name of T&P Quantity
1. Excavator As per site
requirement
2. Shovel
3. Crow bars/ Spikes (22 mm.,1.5 MTR)
4. Drilling machine (if required)
5. Excavator (to be hired, if required)

After pits are excavated, next step is anchoring for the guys.
















10.0 GUY ANCHORING


10.0 GUY ANCHORING

The procedure for anchoring and requirement of T&P is given below:-

Procedure:-

1. Insert Tripleye anchors rod (Guy adopter) in pit hole.
2. It should come out at bottom of pit hole.
3. Fit cross plate anchor with anchor rod and tighten with nuts as per
approved drawing.
4. Now back-fill the pit with the excavated soil and compact the soil
properly.
5. The top of anchor rod is to be connected with guy wire with the help
of pre-formed armour grips. These grips should have not been
used more than 2-3 times.
6. In case of screw/ marsh anchors compaction of soil is not required.
The top end of screw anchor rod/ extension rod shall be connected
with guy wire.

Tools & Plants

S.N. Name of T&P Quantity and type
1. 9/16 EHS Guy Wire As per site
requirement
2. Guy Assembly consisting of
(i) Wire Rope Thimble (Guy Wire
Thimble)
(ii) Big Grip Deadend (Preformed Guy
Grip)


3. Cross Plate Anchor Assembly consisting of
(i) Tripleye Anchor Rod (Guy Adaptor)
(ii) Cross Plate Anchor

4. Marsh Screw Anchor Assembly consisting of

(i) Tripleye Guy Adaptor
(ii) Triple Helix Lead Section
(iii) 10 Foot Extension
(iv) Fork Installation Tool
(v) Fork Installation Tool Body
(vi) -10 4 Hex head cap bolt
(vii) -10 Hex Standard Nut


5. Rock Bolt Anchor Assembly consisting of

(i) Rock Bolt Anchor Assembly Part
(ii) S1 Key Hole Bearing Steel Plate
Washer
(iii) E1 Eye Bolts



Once the four anchors are ready, tower erection can be started.
Remaining anchors can be made ready while carrying out erection of
towers as the same are required before stringing activity only.














11.0 GENERAL ASSEMBLY AND ERECTION
INSTRUCTIONS FOR THE STRUCTURE


11.0 GENERAL ASSEMBLY AND ERECTION
INSTRUCTIONS FOR THE STRUCTURE
11.1 GENERAL ASSEMBLY :
Once the type of ERS structure has been determined, the materials
required have been secured and at least four anchors are ready,
assembly of the structure can begin. In certain cases, such as where the
column is being Whipped up, it may be necessary to secure the
foundation using screw anchors, in order to resist the erection loads on
the foundation. (Figure 16 shows how to calculate the erection forces on
the foundation).
If the foundation must be placed on unstable ground, one or two guy
plates can be placed between the foundation and the Gimbal to attach
permanent guy wires from these guy plates to permanent anchors, in
order to stablize the foundation.

Above the Gimbal the required tower sections can be bolted together
along with any guy plates and box sections which may be called for by the
design. The bolts used on the structures should always be the special
ERS bolts. These bolts are 5/8-11 zinc-plated steel bolts with the stamp
ERS on the head. For proper functioning of the tower, it may be
ensured that only these bolts be used and other non standard 5/8-11
bolts should not be used. If a column is overloaded these specially
designed ERS bolts are designed to fail before any of the welds (See
Figure 17). If no ERS bolts are available, 5/8 inch SAE grade 5 or 16 mm
grade 8.8 metric bolts can be used; however, the welds may break before
the bolts if the section is overloaded.

For all connections including two or more guy plates, the standard ERS
bolt i.e. 3-1/2 inch or 90 mm in length with 2-1/2 inches of thread length
can be used. In all cases a lock washer should be included, and the bolts
torqued to 70 to 90 foot-pounds or 95 to 120 Newton-meters. If high
strength non-ERS bolts are used, more than one length will be needed
typically 2-1/2 inch or 65 mm for most connections and 3-1/2 inch or 90
mm for connections of two of more guy plates.

As a general rule, the shorter column sections, 7 and 14 foot, should be
assembled closest to the foundation. These sections are slightly heavier
per unit length than the 21 foot sections and by assembling them on the
lower portion of the tower more of the weight is kept at the bottom of the
structure. The column sections should be mounted so the flat portion of
the side lattice angles are facing up. Structurally, it makes no difference
which end of the section is up or down, however, positioning the lattice
flats up makes climbing the towers easier.
Each column section has two pins, one on each end. These pins can be
used to help align two sections being assembled. For structural
purposes, the pins can be positioned in any of the three holes on the
column end plate, although it is recommended that they be positioned
diagonally opposite.

Figure-16
Positioning the pins diagonally opposite will maintain the same back and
forth pattern of the lattice angles between column sections and thus
provide a more consistent climbing pattern. There is one short pin and
one long pin, which allows one pin to be installed first so the column
section can be rotated on the first pin until the second pin is inserted.

When attaching the insulator/ hardware assemblies to the ERS structure,
care should be taken to prevent twisting of the polymer suspension
insulators. Torsional loading combined with tensile loading can reduce
the ultimate strength of the insulators and cause premature failure.


















Figure-17























Figure-18








11.2 GENERAL INSTRUCTIONS FOR ERECTION OF THE
STRUCTURE

There are a variety of erection techniques which can be used on the ERS
structures. Each particular utility develops their own specific techniques
depending on the type of equipment which they have available, the type
of terrain that they must work in and the type of ERS structure that they
will be erecting. Keeping this in mind, only the most commonly used
techniques are described. As the user gains more experience with the
structures, other techniques and methods can be tried as long as the
basic rules explained below are maintained.

A common method of erecting the structures is using Gin Pole. However,
to expedite restoration work tilting up the structure with a crane or
helicopter can also be adopted. If the structure has been assembled with
the foundation in its proper location with the structure horizontal, the
structure can be picked at or near the top and tilted into place pivoting at
the Gimbal. It is important to note that the ERS structure is fabricated
from aluminium and is very flexible compared to steel. When picking the
top end of a 105 foot (32 meter) column, with the base fixed to the
ground, the top end will deflect or raise approximately 20 inches or 500
mm before the Gimbal begins to rotate (see Figure 18). If the 105 ft
column is made up of 21 ft sections, and the maximum bending moment
is calculated, 27 percent of the bending capacity of the structure is utilized
when tilting up as described above. For a conservative reference use
Figure 19 and 20 to determine the maximum lifting load T1 and the
maximum column length that can be lifted. Figure 19 assumes an ERS
column made up of only 14 ft sections, with eight guy plates at the top,
and a reasonable amount of guy wire attached to the structure. Figure 20
assumes an ERS column made up of only 14 ft sections, with eight guy
plates and three box sections at the top, and a reasonable amount of guy
wire attached to the structure. When lifting with a helicopter, tests have
indicated that the lifting load T1 will increase by approximately 10% due
to helicopter downwash on the structure.

To minimize the bending moment on a simple column when tilting it up
with a crane, the column should be picked up approximately one third of
the distance from the top (T2 in Figures 19 and 20). Column with box
sections, or other top-heavy loads, should be picked up closer to the top.
Special caution should be taken when erecting tall columns over 120 feet
or 36 meters.

If the foundation is not set in position when erection begins, the best
method of transporting and setting an assembled column is to choke the
structure slightly above the center of gravity (T3 in Figures 19 and 20).
The structure can then be moved so that the foundation is in its proper
location and the structure can be tilted into position.




Figure-19




Figure-20



Since it is very difficult to plumb the column with a crane or helicopter, it is
advisable to use the crane or helicopter to get the structure close to plumb
and then use chain hoists on the guys to bring the structure into plumb.
Past experience has shown that some form of positive hold on the guys is
essential. Chain hoists and come-along attached to the guys should be
used when adjusting the position of the tower. Block and tackle should
not be used. If a block and tackle is used and the column gets too far out
of plumb, the force of the towers movement may be too great for the
block and tackle and the column could fall.

The allowable bending moment on a column is 140,000 foot-pounds or
190,000 Newton-meters. This bending moment should not be exceeded
during construction. Figure 19 and 20 should give maximum lifting loads
and maximum column lengths. If a particular application is outside of
these parameters, the actual bending moments can be calculated by
using the ERS computer programs. If this is not available, the weight of
each component and their length can be used to perform a simply
supported beam analysis. The end support reaction of the simply
supported beam will provide T1. The maximum bending moment can
also be found from this analysis.

As a general rule, when erecting a tall column, over 100 feet or 30 meters,
and any column which will be subjected to high winds, the column should
have intermediate guying. This intermediate guying will reduce the
bending of the column due to wind loads, and dramatically increase the
loading capacity of the structure (See Figure 21). It is important to keep
the column straight when adding intermediate guying. Do not over
tension the intermediate guy so that a bend is introduced into the column
(See Figure 22). The intermediate guys can be attached on a guy plate
installed between sections for this purpose. There are also four holes on
the end flange of each section, one on each side, which can be used for
attaching intermediate guys after the ERS structure is installed. These
same four holes can and should be used as attachment points for
construction guys when using the section method of Gin Pole erection.

Except under unusual circumstances, it is important to guy all structures
at the same height as the load. Do not connect the load to the structure
at one height and guy the structure at the section below or above, as this
will create bending loads on the structure which may limit its capacity.
This rule is also true for the box section, back guy the box section to
minimize shear on the box section. In cases where a load is being applied
to both the top and bottom of a box section, such as in a heavily loaded 3
bundle deadend, it is best for the structure to be guyed back at both the
top and bottom of the box section.































Figure-21



















Figure-22

The guy plates on the ERS have 6 points where guys or loads can be
attached. Each of these six attachment points can hold an ultimate load
of 30,000 pounds or 134 kN. It is important to insure that the maximum
design load on any one of these points is below this limit (See Figure 23).
In cases where the maximum load may be above this limit, multiple guys
should be attached to more than one attachment point. It is critical that
the guy attachments have a large degree of flexibility and not be rigid
connections. If a guy is attached without this degree of articulation,
wedging or bending of the attachment hardware may occur, and the
attachment may fail. For this reason, it is recommended that an anchor
shackle with bolt nut and cotter pin and a steel wire rope thimble be used
with a preformed guy wire grip at the guy plate.


Figure-23

It is important when tensioning the top guys as well as the intermediate
guys, that they not be over tensioned. In most cases, a pretension of
about 500-1000 pounds or 2-4 kN, or simply taking the slack out of the
line, is sufficient. In some instances, such as a deadend or angle tower,
the pretension should only be enough to keep the column straight under
normal conductor loading conditions. It is not recommended that the
structure be raked back as is often done with wooden poles. After the
conductor is clipped in, the guy wire tensions should be re-checked and
adjusted to insure a straight column (see Figure 22).















12.0 ERECTION PROCEDURE USING A GIN POLE

12.0 ERECTION PROCEDURE USING A GIN POLE

The Gin Pole can be used to either tilt up an ERS column or build an ERS
column section by section. Both of these methods will be discussed;
however all the items covered in section 14.0 also apply to tilting up an
ERS column with the Gin Pole.

12.1 TILTING UP THE ERS COLUMN WITH THE GIN POLE

Before attempting this method, determine the loads in the winch line and
the maximum length of ERS column that can be erected using this
method. Refer to Figure 24 to determine the maximum winch or lifting
load T4 and the maximum column length. In order to be conservative,
Figure 24 assumes an ERS column made up of only 14 ft. sections, with
eight guy plates at the top, and a reasonable amount of guy wire attached
to the structure. If a particular application is substantially different from the
ERS column described above, the actual lifting loads can be calculated as
demonstrated in Figure 16.

The winch line roller assembly and the Gin Pole attachment should be
assembled to the aluminium Gin Pole. The attachment is designed to fit
on any one of the four sides of the bottom channel, and between the 1
inch reinforcing plates of ERS Gimbal Joint. Cut four pieces of rope.
These ropes will be tied to the ring on the top of the Gin Pole (derrick) and
will be used to stabilize the Gin Pole during tower erection. Place the
winch line in the roller assembly of the Gin Pole and tilt up the column.
The column being tilted up should be guyed to each side to prevent the
column from becoming unstable and rotating to one side. These two side
guys should be attached to two separate anchors that line up with the
foundation in a straight line on the ground perpendicular to the plane that
the ERS column is being raised in. Since the ERS Gimbal axis is
approximately 2 ft. off the ground, tension in these two side guys should
be released as the column is raised to the vertical position. Failure to
leave sufficient slack in the side guys as the tower is raised can cause the
side guys to break. The column should also be guyed on the side
opposite to the winch line side to prevent the column from tipping over if it
is raised past vertical.

12.2 BUILDING AN ERS COLUMN SECTION BY SECTION
WITH THE GIN POLE

An important advantage of the Modular Emergency Restoration System is
that structures and conductor can be erected and installed by hand using
the Gin Pole (derrick). The following detailed procedure can be used
when no heavy equipment is available.

12.2.1 Initial preparation requirements:

1. Cut four pieces of rope. These ropes will be tied to the ring on the top
of the Gin Pole (derrick) and will be used to stabilize the Gin Pole
during tower erection. The length of the ropes should be sufficient to
build the entire length of the structure and have the ropes at a 45
degree angle from the top to where the ropes are tied to the temporary
anchors. For a 125 foot or 38 meter high tower, the ropes should be at
least 200 feet or 61 meters in length. See Figure 25.



Figure-24


2. Provide anchors for the Gin Pole. If permanent anchors cannot be used
then temporary anchors need to be used to attach the 200 foot or 61
meter Gin Pole mast ropes. One method of making temporary anchors is
to use steel bars approximately 4 feet or 1.2 meters in length, 1 inch or 25
mm in diameter and pointed on one end. Depending on soil conditions 1
to 3 bars should be used at each of the four Gin Pole anchor locations.
Typically, it is the same type of bar that is used to stake down the
foundation plate. It is a good idea to have several extra bars, about 20, on
the erection site.

3. Provide a sufficient quantity of rope. Polypropylene rope, 5/8 or 16 mm in
diameter, is typically used to guy the Gin Pole and can be used for a
hoisting rope. However, never use polypropylene rope to temporarily guy
the tower. If a 125 foot or 38 meter tower were to be erected, the
minimum total amount of rope required would be approximately 2,100 feet
or 640 meters, the ropes should be cut into the following lengths :

(i) 200 foot (60 m) lengths 4 Nos.
(ii) 300 foot (90 m) lengths 4 Nos.
(iii) 15 foot (5 m) lengths 2 Nos.

4. Provide the following miscellaneous equipment required to erect the
towers, assuming block permanent anchors and temporary stake anchors
are used;

(i) Sledge hammers (8 lb, or 3.6 kilogram) 2 Nos.

(ii) Roller sheaves with side opening and hook 4 Nos.
(1 ton or 9000 Newton safe working load minimum)

(iii) Adjustable wrench (0 to 2 inch or 50 mm, jaws) 1 No.

(iv) Hydraulic wire cutters 1 No.
(capacity for 9/16 inch EHS guy wire)

(v) Guy wire spool stand 1 No.

5. Precut all steel guy wires to be used on the tower.

6. Locate and mark foundation and anchor locations on the ground.

7. Dig anchor holes if plate anchors are used instead of block weight
anchors. Install anchor plates. Back fill in 2 foot or 0.6 meter lifts. Be sure
to use a hand tamper on each 2 foot or 0.6 meter lift. It is important that
the back filled soil be compacted. Use water if necessary. If standard
plate anchors are used, the anchor rod should be on a 45 degree angle
and approximately 1 foot or 0.3 meter of the anchor rod should be above
ground.
8. Locate and stake 4 temporary Gin Pole rope anchors (4 foot or 1.2 meter
steel rods). At a minimum, these anchors should be as far from the
foundation as the tower is tall when completely erected.

9. Place one sheave on the top ring of the Gin Pole. Place 2 sheaves on a
wire cable or sling that has been wrapped around the foundation. String
one 300 foot or 91 meter rope through the sheaves at the base of the
foundation and through the sheave at the top of the Gin Pole.

12.2.2 Procedure for Gin Pole (derrick) erections of the ERS
towers:

1. Stake foundation at its proper location.

2. Manually tip the Gimbal Joint onto the foundation and bolt it in place. Do
not remove the turn buckles from the Gimbal Joint. If the top of the Gimbal
Joint is not level, adjust the four turn buckles to level it.

3. Tip up the Gin Pole along the Gimbal Joint. Pull back and tie the four 200
foot or 61 meter Gin Pole mast ropes to their respective anchors. If the
Gin Pole is to be used for hoisting insulators, stringing blocks and other
materials once the tower is built, be sure to locate the Gin Pole on the
most convenient side of the tower.

4. Erect the first column section by tying the mast rope to the column section
above its center of gravity (see Figure 25). Do this in such a manner that
the point of connection is centered on the side of the column that the Gin
Pole is on. Tie two tag lines to the column being lifted (300 feet or 91
meters long one on the top and one on the bottom). The column section
should be hoisted from the opposite side of the structure that the Gin Pole
is attached to. To manually hoist the column section use 15 to 20 men to
pull the 300 foot or 91 meter hoisting line. Using the tag lines (3 men on
each tag line) to keep the column section being hoisted perpendicular to
the tower. Lower the column section onto the Gimbal. Make sure the pin
guides slide into the holes properly. Bolt the connection with 8 bolts.

5. Pull the Gin Pole up the tower to its next location by attaching a sheave or
snatch block to one of the one inch holes centered on either side of the
column flange. Run the second 300 foot or 91 meter rope through the
another sheave at the foundation and through the sheave on the top of
the tower flange and attach it to the ring on the bottom end of the Gin
Pole. By slacking off on the four Gin Pole guys and pulling on the second
hoist rope the Gin Pole can be safely raised to the next location. When
the proper height above the tower is reached, place the hook on the
bottom of the Gin Pole over one of the lattice angles. This hook usually
slides to the corner of the lattice angle. Secure the Gin Pole at the bottom
ring and near the top flange using the two 15 foot or 4.6 meter tie ropes
(regularly inspect these ropes for wear, and replace as needed).

6. Readjust and tighten the Gin Pole rope guys so the top of the Gin Pole is
correctly located. Repeat the hoisting procedure that was described in
paragraph no.4. Note that the higher the column sections are to be
hoisted the farther away from the tower the tag line personnel must be.

7. Place temporary steel guys at proper intervals as the tower height
increases. The guy wires should be attached to the permanent anchors.
When the temporary steel guys have been put in place, the turnbuckles
on the Gimbal should be loosened and completely removed.

8. In difficult terrain, it may be easier to install the 21 ft. column sections first,
and the smaller 7 ft. and 14 ft. column sections later, as the structure
height increases.

9. Once the entire tower has been erected it should be plumbed and the
guys should be properly tightened and the performed grips should be
applied.

10. At this point, the Gin Pole can either be left in place or tipped at an angle
to assist in hoisting insulators, stringing blocks or conductors. Be sure the
Gin Pole is properly roped to the columns before lifting heavy loads.

Figure-25















13.0 ERECTION PROCEDURES USING A BOOM-
TRUCK OR LIGHT DUTY CRANE



13.0 ERECTION PROCEDURES USING A BOOM-TRUCK
OR LIGHT DUTY CRANE

There are several techniques that can be used to erect an ERS structure
with a crane. The choice of technique depends on the type and capacity of
the crane available. One technique has already been partially discussed in
section 11.2. With a large crane, the entire column can be bolted together
horizontally on the ground. The entire structure including foundation can
be moved to the proper location, if needed, and the crane used to raise the
top of the column to the near plumb position until the structure can be
secured and plumed using chain hoists and come-along attached to the
guys. This method requires the crane to lift the end of the column while
the boom is extended at least one half the height of the ERS column away
from the cranes foundation, this necessitates a large crane. It also
requires a skilled crane operator to raise a load and swing the crane boom
as the end of the ERS column raises.

With two cranes, ERS structures have been erected where one larger
crane remains almost stationary lifting the top end of the ERS structure
(which was assembled and positioned near the final location of the
foundation). At the same time, a smaller mobile crane lifts the bottom end
of the ERS structure (including foundation plate) and moves the foundation
to its final position. In this method the large crane never has to swing its
boom.

However, for most applications where only a small crane or boom truck is
available or can get to the job site, the following technique is most useful.
This technique can also be used with larger cranes.

The following steps are referred to in Figure 26

1. Position the foundation in the desired location and stake into place.

2. Construct the column on the ground adjacent to the foundation. The
center of the column should be located approximately at the
foundation. Leave the turnbuckles on the Gimbal (but loosen the lock
nuts).

3. Install pre-measured guys to the column, include temporary guys if
required.

4. Locate the center of gravity (CG) by picking-up the column at various
locations. Pick the column by choking all four main angles with a steel
or nylon strap. Locate the straps one to two feet above the center of
gravity, so that two linemen can lift the Gimbal.

5. Begin raising the column using the winch line. The boom should only
require minor adjustments in position. Have two crewmen walk the
Gimbal section towards the foundation.

Figure-26

6. Once the column is vertical, with the Gimbal one foot off the ground,
remove all four turnbuckles from the Gimbal.

7. Position the column over the foundation and bolt the Gimbal and
foundation together. Maintain a minimal amount of tension on the
winch line, enough to keep the column vertical without pulling the
foundation upwards.

8. Attach the guys to their anchors and begin tensioning. Use the guy
wires, not the boom, to plumb the column. After the guys are installed
the winch line can be slacked off.

9. Have a crewman climb the column and release the sling from the
column.














14.0 ERECTION TECHNIQUE INVOLVING
TILTING UP OR WHIPPING UP THE ERS
COLUMN WITH A WINCH LINE



14.0 ERECTION TECHNIQUE INVOLVING TILTING UP
OR WHIPPING UP THE ERS COLUMN WITH A
WINCH LINE

Entire ERS columns have been erected using a winch line placed over the
top of a standard Gin Pole (derrick) and attached to the top of the ERS
column. Another method is to raise the top of the ERS column with a
small boom and simply pull or whip up the column with a winch line. Still
a third method is to use one already erected ERS column as a Gin Pole
and tilt up another ERS column with the winch line.












Figure-27




When tilting up an ERS structure using a winch line and standards Gin
Pole (derrick), another ERS structure, or when whipping up a column,
the foundation will have a tendency to move horizontally in the direction of
the pull, and to tip up during the initial stages of the lift. As more vertical
weight of the column acts on the foundation the tipping will subside. This
tendency should not pose any problems, although it is recommended that
screw anchors be used to secure the foundation when using these
erection techniques(see Figure 27). Figure 16 shows the types of loads
which are present when tilting up or whipping up a column. This type of
analysis should be performed to determine the winch line load, uplift and
horizontal load on the foundation as well as to insure that the capacity of
the structure is not exceeded. In using the procedure shown in Figure 16
for analyzing an ERS column being tilted up, set the dimension B to the
height of the standard Gin Pole or the winch line attachment point on an
adjacent ERS structure.

The column being tilted up or whipped up, should be guyed to each
side to prevent column from becoming unstable and rotating to one side.
These two side guys should be attached to two separate anchors that line
up with the foundation in a straight line on the ground perpendicular to the
plane that the ERS column is being raised in. Since the ERS Gimbal axis
is approximately 2 feet off the ground, tension in these two side guys
should be released as the column is raised to the vertical position. Failure
to leave sufficient slack in the side guys as the tower is raised can cause
the side guys to break. The column should also be guyed on the side
opposite from the winch line to prevent the column from tipping over if it is
raised past vertical.














15.0 SPECIALISED ERECTION PROCEDURE
USING A HELICOPTER


15.0 SPECIALISED ERECTION PROCEDURE USING A
HELICOPTER

Three methods are typically available for erecting an ERS column using a
helicopter. The method chosen usually depends on the type and lift
capacity of the helicopter and the skill and training of the pilots.

15.1 FLY IN AND LANDING OF AN ENTIRE ERS COLUMN
USING A HELICOPTER

This method requires the largest helicopter, of the three methods. The
ERS column is usually assembled on the ground at a marshalling yard
(see section 11.1). The permanent guy wires are pre cut and attached to
the column and brought down to the ERS Gimbal joint, rolled up and
attached to the Gimbal with tape or a tie rope. Two metal or nylon slings
are attached to diagonally opposite corners of the top of the ERS column
(as seen in Figure 28). This will ensure that the column hangs straight.
Next, these slings are attached to a lift line of approximately 100 feet or
30 meters in length and to a ring with sufficient weight that will allow the
ring and lift line to drop off the remote control release hook mechanism on
the helicopter. For emergency conditions, and for ease of release each
helicopter should be equipped with a remote controlled release
mechanism as shown in Figure 28.
Discuss and plan the erection procedure and emergency procedures
before beginning. Use a helicopter pilot with external load moving
experience. Provide adequate radio communication equipment for the
helicopter and ground crew. Provide for dust abatement around the
erection site to improve visibility.

Lift the column, first pivoting about the Gimbal then lifting the entire
column. As the helicopter approaches the erection site, the area where
the foundation is to be placed should be clearly marked. As the helicopter
lowers the ERS structure, static electricity can be drained off by first
touching the structure on the ground. A foundation crew will grab the
foundation and help guide it to its proper location, while the helicopter
hovers. Once the foundation is located, the foundation crew should stake
the foundation. At the same time, one crew for each permanent guy wire
will detach the guy wire from the Gimbal of the ERS structure, and put the
guy wire in wire grips and attach these grips to the anchors with chain
hoists.

While this is taking place, the helicopter should not try to hold the
structure plumb, as the structure will be unstable, making it difficult for the
guy wire crews to attach the guy wires to the anchors. Instead, the
helicopter should hold the ERS structure in one position, approximately 5-
10 degrees from vertical.


Figure-28

Once four of the permanent guy wires are attached to their anchors and
tightened up, the helicopter can slowly lower to test if all the guy wires and
anchors are properly installed. Once this is verified, the helicopter can
release the ERS structure using the remote controlled release hook. It is
important to ensure that there is enough weight on the ring of the lift line
to release the lift line from the hook, otherwise the pilot may pull away
without releasing the lift line.

Once the helicopter has left, the crews can finish plumbing the structure
and staking the foundation.

15.2 TILTING UP AN ERS COLUMN WITH A HELICOPTER

This method may also require a large helicopter (refer Figure 19 and 20
for lifting loads). The ERS column is usually assembled on the ground at
the site (see section 11.1). The permanent guy wires are pre cut and
attached to the column and brought out to the permanent anchors. Two
metal or nylon slings are attached to diagonally opposite corners of the
top of the ERS column (as seen in Figure 28). Next, these slings are
attached to a lift line of approximately 100 feet or 30 meters in length and
to a ring with sufficient weight that will allow the ring and lift line to drop off
the remote control release hook mechanism on the helicopter. For
emergency conditions, and for ease of release, each helicopter should be
equipped with a remote controlled release mechanism as shown in Figure
28.

Discuss and plan the erection procedure and emergency procedure
before beginning. Use a helicopter pilot with external load moving
experience. Provide adequate radio communication equipment for the
helicopter and ground crew. Provide for dust abatement around the
erection site to improve visibility.

Attach the lift line to the helicopter, then tilt up the column. (see section
14.0).

The helicopter should not try to hold the structure plumb, as the structure
will be unstable making it difficult for the guy wire crews to attach the guy
wire to the anchors. Instead the helicopter should hold the ERS structure
in one position approximately 5-10 degrees from vertical. If more than one
ERS column is to be tilted up at this site, it is a good idea to tie markers or
flags to the guy wires so that the helicopter pilot can more easily see the
guy wires when additional columns are raised.

Once four of the permanent guy wires are attached to their anchors and
tightened up, the helicopter can slowly lower to test if all the guy wires and
anchors are properly installed. Once this is verified, the helicopter can
release the ERS structure using the remote controlled release hook. It is
important to ensure that there is enough weight on the ring of the lift line
to release the lift line from the hook, otherwise the pilot may pull away
without releasing the lift line.

Once the helicopter has left, the crews can finish plumbing the structure.
15.3 SECTION BY SECTION METHOD OF ERECTING AN
ERS COLUMN USING A HELICOPTER:

This method is not recommended unless the helicopter pilots and crews
have previously trained together. If they have not trained sufficiently, a
better method for erecting the ERS structure would be for the smaller
helicopter to transport all the material to the erection site and use the
section by section method of erecting an ERS with the Gin Pole. (see
section 12.2).

To use the section by section method of erecting an ERS structure with a
helicopter follow the procedure below :

15.3.1 Initial preparation Requirements:

1. Cut four lengths of 9/1619 EHS guy wire approximately 330 feet or
100 meters in length. Attach performed guy wire big grips with wire
rope thimbles to both ends.

2. Provide eight automatic wire grips eight 3-ton chain hoists, and six
metal slings.

3. Discus and plan the erection procedure and emergency procedures
before beginning. Use a helicopter pilot with external load moving
experience. Provide adequate radio communication equipment for the
helicopter and ground crew.

4. Provide for dust abatement around the erection site to improve
visibility.

5. Discharge static electricity build up in the column sections by
grounding the column prior to lowering the tag lines to the linemen on
the tower. This can be done with a small metal wand by a lineman, or
by touching the structure to the ground.

15.3.2 Procedure for Section by Section Helicopter Erection of
ERS towers:

1. Level a small area for the foundation. Bring in the foundation and
place it with the helicopter. Securely stake the foundation to the
ground. Next, bring in the Gimbal and manually place it on top of the
foundation with a crew of four to six linemen. Then bolt the Gimbal to
the foundation. Generally (if space permits) the tie rods on the Gimbal
are released and the Gimbal is lowered to the ground and one or two
additional column sections are brought in, and a light-duty helicopter is
used to tilt up the first 21-35 feet or 6-11 meters of column sections.
However, if space is not available then the tie rods on the Gimbal are
left in place, and the top flange of the Gimbal is levelled by adjusting
the tie rods to await the next column section.



Figure-29

2. Lift each column section with the helicopter by attaching two metal or
nylon slings to diagonally opposite corners of the top flange as seen in
Figure 29. This will ensure that the column hangs straight. Next, attach
the slings to a 100 foot or 30 meter lift line and to a ring with sufficient
weight that will allow the ring and lift line to drop off the remote control
release hook mechanism on the helicopter. For emergency conditions,
and for ease of release each helicopter should be equipped with a
remote controlled release mechanism as shown in Figure 29. 10 foot
or 3 meter tag lines should be attached to diagonally opposite corners
at the bottom of the column being lifted.

3. Fly in the first column above the Gimbal joint and lower the column
down onto the top of the Gimbal joint using the tag lines to guide it.
This is shown on Figure 29 Some pilots prefer the linemen to pull the
column down onto the structure while the helicopter maintains a
neutral buoyancy or only a slight lifting force on the column section.
Once the column section has landed, one bolt is placed in each of the
diagonally opposite corners by the linemen. While the linemen are
doing this, it is best that the helicopter pilot lowers the helicopter to put
slack in the lift line. This is shown on Figure 30. If the helicopter pilot
tries to maintain tension in the line, quite often the helicopter will drift
to the side and begin to pull the column off the top of the structure.

4. Hand tighten both bolts in the diagonally opposite corners, move away
from the structure and release the lift line.

5. Attach one end of the four 330 foot or 100 meter steel guy wires to the
structure on each of the four corner legs using steel slings and
shackles. These guy wires should be located approximately 10 feet or
3 meters below the top of the column (see Figure 29). This will ensure
that the next column section does not become tangled in the
intermediate construction guys.

6. Bring in the next column section and grab the tag lines and pull the
column down on to the structure. Insert the long 6-inch or 152 mm pin
on the column being flown in, into one of the matching holes in the
erected column. Rotate the column and locate the shorter 4-inch or
102 mm pin in its matching hole. Bring down the column by pulling on
diagonally opposite corners of the structure (see Figure 29). Lower
the helicopter to put some slack in the lift line while the two linemen
tighten the bolt and nut in diagonally opposite corners of the flanges.
The linemen should climb down below the temporary guying, which
the pilot releases the hook. It is important to ensure that there is
enough weight on the ring of the lift line to release the lift line from the
hook, otherwise the pilot may pull away without releasing the lift line.
Once the lift line is released, the linemen can climb back up to the
flange and finish bolting all eight ERS bolts to attach the flange
section.



Figure-30

7. Attach the four 330 foot or 100 meter guy wires to more permanent
locations either at the mid point of the flange or at a guy plate on the
structure as the height of the column increases (refer to Figure 29).
Attach the other end with preformed guy wire grips and thimbles to the
matching flanges with a anchor shackle. Put the steel guy wire into
automatic wire grips, using 3-ton chain hoists to tension the guy wires
to the permanent anchors. Release the lower temporary guys,
attached with slings, and use that end of the guy wire to guy at higher
locations on the structure. It is recommended that no more than 42
feet or 13 meters of free standing column be erected without the guy
wire being moved up and re-anchored. The emergency Restoration
Structure can be erected using a light-duty helicopter, by following the
preceding steps.
















16.0 CLIPPING-IN PROCEDURES

16.0 CLIPPING-IN PROCEDURES

16.1 RESTORING CONDUCTOR AND CLIPPING-IN

Once the Lindsey Modular Emergency Restoration structures are erected,
along with their associated hardware and insulators, the conductor may
have to be restrung between the intact permanent towers and through
the Lindsey Modular emergency Restoration Structures. Standard
tension stringing methods should be used for this operation, no special
precautions are needed for the ERS. The stringing travelers or rollers
can be attached to either the Universal Yoke Plate or the End Cap
Adapter with an Anchor Shackle and Chain Link, or just an Anchor
Shackle. Depending upon the anticipated time that the ERS are to remain
in service, the conductor may be left in the stringing travelers, or the
conductor can be clipped-in

If cranes and bucket trucks are available, clipping-in relatively straight
forward. The following procedures can be used if equipment access to
the ERS structure is limited.

16.2 CLIPPING-IN PROCEDURES FOR CHAINETTE
STRUCTURES

1. After the two columns of the Chainette structure have been erected
and both columns are vertical and the top cross rope guy is still slack,
raise the Chainette hardware and insulator assembly and attach it to
the top guy plates on each column.

2. If the conductor is to be strung through the bundle travelers, raise the
bundle travelers with the Chainette hardware insulator assembly.
Connect the bundle travelers to the universal yoke plate. A tag line
should be attached to the frame of each bundle traveler, and a pilot
line should be threaded through the center sheave of each bundle
traveler.

3. Once the Chainette insulator hardware assembly has been attached to
the top guy plates, use the 3-ton chain hoists at each of the anchor
locations to tilt the columns outward to take the slack out of the top
cross rope guy.

4. String the 3-bundle conductor using standard tension stringing
methods. Once the conductors are sagged, the Chainette structure
can be clipped in.

5. To provide access to each phase place a ladder (or boatswains chair)
with rollers on the top cross rope guy. Attach tag lines to the ladder to
position it horizontally. Attach a Chainette Clip-In Sling to the same
guy plate shackle that is used by the top cross rope guy (Refer to
Figure 31).


Figure-31

6. Attach a 3-ton chain hoist to the shackle on each of the yoke plates of
the clipping-in sling. Referring to Figure 31, the clipping-in of a two or
three conductor bundle would require using the chain hoist and a
conductor lifting hook to lift the first outside sub-conductor into the
outside position of the universal yoke plate. The U-bolts on the
suspension clamp should be tightened to approximately 35 ft-lb. or 47
Newton-meters torque.

7. For a three conductor bundle, raise the center sub-conductor and
temporarily position it on the second hole of the universal yoke plate.
(Refer to Figure 31) For additional clearance a chain link can be
added to the anchor shackle.

8. Raise the last or inside conductor using the chain hoist. Once the
load is taken off the bundle traveler attach the tag line to a small
snatch block on the fourth hole of the universal yoke plate and use it to
lower the bundle traveler.

9. Once the bundle traveler is lowered, position the third conductor and
clip it in to the fifth bottom hole of the universal yoke plate.

10. Once the third conductor is clipped in, lower the second conductor and
attach it to the clevis eye link. This completes the 3-bundle triangular
geometry. (Refer to Figure 31).

11. Move to the next phase and repeat this process.

16.3 CLIPPING-IN PROCEDURES FOR HERRINGBONE
AND FOUR-COLUMN STRUCTURES.

1. Once the 4-column or Herringbone structures are erected, and the
cross guy ropes are tightened by tightening up on the anchor guys, the
Vee-string insulator hardware assemblies can be raised to their
appropriate positions. The single conductor or bundle conductor
travelers should be attached to the universal yoke (refer to Figure 32).
A tag line should be attached to each traveler.

2. If the conductor is to be strung through the travelers, raise the
travelers with the Vee-string hardware insulator assembly. A tag line
should be attached to the frame of each traveler, and a pilot line
should be threaded through the center sheave of each traveler.

3. String the conductor using standard tension stringing methods. Once
the conductors are sagged, the structure is now ready for clipping-in.

4. For the Herringbone structure, the Clip-In Sling should be attached to
an open hole on each side guy plate (refer to Figure 32).

5. The lineman should position himself on a ladder (or boatswains chair)
with rollers attached to the cross rope guy (refer to Figure 32). Attach
a 3-ton chain hoist to the shackle in the clip-in sling yoke plate, and
use an conductor lifting hook to lift the conductor out of the single or
bundle traveler.

6. Once the conductor weight is removed from the traveler, lower the
traveler using the tag line and a snatch block attached to one of the
working holes of the universal yoke plate.


Figure-32

7. Attach the conductor suspension clamp to the conductor, tightening
the U-bolts to approximately 35 ft-lb. or 47 Newton-meters of torque.
Attach the suspension clamp to the anchor shackle attached to the
yoke plate.

8. Move to the next phase and repeat this process.

16.4 CLIPPING-IN PROCEDURES FOR HORIZONTAL-VEE
STRUCTURES.

1. After erecting the structure (utilizing the Gin Pole), leave the Gin Pole
attached to the side of the column. Secure the hook over the diagonal
bracing of the Emergency Restoration Structure, and securely fasten
the bottom ring of the Gin Pole to the Emergency Restoration
Structure with ropes. After the Horizontal Vee hardware insulator
assembly is attached to the box section and top guy plate, position the
top back guy rope of the Gin Pole to a anchor shackle attached to the
top guy plate (see Figure 33). Attach an additional tie-back rope to the
top ring of the Gin Pole. A 3-ton chain hoist (or sling and chain hoist,
depending upon length) should be attached to the top ring of the Gin
Pole. Swing the Gin Pole out over the conductor position as shown in
Figure 33.

2. Secure the additional tie-back rope to a anchor shackle located on the
45/45 degree guy plate (see Figure 33).

3. If the conductor traveler is light enough, it can be raised with the
Horizontal Vee insulator hardware assembly and attached at the same
time the insulator and hardware is attached to the structure. If,
however, the traveler is too heavy, raise the traveler on the rigging line
of the Gin Pole (see Figure 33). The traveler should have a pilot line
threaded through the sheave of the traveler. The lineman can position
himself at the conductor attachment point by positioning a sling (using
hot sticks) over the hardware end of the horizontal post insulator, and
attaching a platform to the sling and tying the platform to the structure
(see Figure 33).

4. The conductor should be strung using standard conductor tension
stringing methods. Once the conductors are sagged, the structure is
now ready for clipping-in.

5. The lineman can position himself at the conductor attachment point
and use the 3-ton chain hoist to lift the conductor up out of the traveler.

6. Once the conductor is lifted up out of the traveler, the traveler can be
lowered using the rigging line already attached to the top of the Gin
Pole. The lineman should attach the conductor suspension clamp to
the conductor tightening the U-bolts to approximately 35 ft-lb. or 47
Newton-meters torque. Then attach the suspension clamp to the
anchor shackle attached to the end cap adaptor.

7. The lineman can now reposition himself at other locations utilizing the
Gin Pole at its present location, or moving it as required.



Figure-33















17.0 DISASSEMBLY OF ERS





17.0 DISASSEMBLY OF ERS

The disassembly of the structure is basically the reverse of the assembly
procedure. Caution should be taken to maintain positive control on the
structure at all times during the lowering of the column. Again, chain
hoists or come-along should be used in place of block and tackle. When
lowering the column section by rotating about the Gimbal joint, care
should be taken to insure that the Gimbal is rotated only in one of the
four directions which will allow the column to rotate 90 degrees. These
directions are indicated by arrows on the Gimbal.

Gimbal rotation beyond about 45 degrees in any of the unmarked
directions could cause structural damage to the Gimbal.

Once the column is on the ground, the sections can be disassembled.
Since the bolts used on the structure are special, it is advised that they
be collected and stored for future use. During disassembly each crew
member should inspect the column sections and hardware for any signs
of overloading or damage.















18.0 PACKING AND STORING OF ERS


18.0 PACKING AND STORING OF ERS

The ERS column section require no special packaging. They should be
stacked in a convenient location until their use is required. The flanges
on the ends of each column section provide a good footing and also
serve to protect the lattice angles from damage. Frequently a 7 foot and
14 foot column section are bolted together to give a 21 foot column
section.

The hardware, insulators and guy plates should be stored in a manner
similar to normal storage practice. It may be wise to identify the material
which is dedicated for emergency purposes. One method is to colour all
hardware components with an unusual colour so that the emergency
material can be readily identified if it is misappropriated. Another frequent
method of storage is to keep the material in a dedicated cargo container.
When an emergency arises, this container can be loaded onto a truck
and all of the required material can be transported to the site. Many
utilities have gone so far as to weld the doors to their emergency
materials container shut to prevent the use of the emergency materials
for other than emergency purposes. Whatever from of storage is used, it
should provide a clean and dry environment.















19.0 MAINTENANCE OF ERS



19.0 MAINTENANCE OF ERS

The column sections should require little to no maintenance, since they
are fabricated from aluminium, other than normal inspection prior to and
after use which might reveal signs of overloading or damage due to
mishandling.

The hardware is galvanised steel and should be checked for signs of
corrosion if the galvanising wears away. Again, there is no regular
maintenance required. The same is true for the insulators. As long as
they are properly stored and handled, they should require no regular
maintenance.

The preformed guy wire grips will not hold their rated ultimate load if the
grit is worn off the inside of the helical wires. If this occurs, the
preformed grips should be periodically replaced after use.

Polymer insulators are relatively rugged, however, during rough field
handling, a skirt or shed may tear. If this occurs, it is best to cleanly cut
off the torn portion of the shed to prevent the tear from progressing into
the polymer layer surrounding the fibreglass core. This may only reduce
the leakage distance by a few inches or centimeter. If a tear extends into
the fibreglass core, the polymer insulator should not be used.















20.0 SAFETY GUIDE LINES DOs and DONTs



20.0 SAFETY GUIDE LINES DOs and DONTs

To ensure safe execution of the job, the following safety precautions are
required to be taken at site. The entire operation need to be conducted
under the supervision of a person trained specially to handle ERS

Dos Donts

Use of safety belt and safety helmets
for the working personnel.
It is to be ensured during
erection that not even a single
guy is over tensioned by
adjusting the tension with the
help of chain pulley blocks.
To ensure suitable marsh anchoring
of guys in sandy soils, heavy
boulders if required should be used
to provide adequate dead weight for
strength of anchors.
Do not use polypropylene rope
to temporarily guy a column
Guy wires to be checked for cuts/
damages before installation
Avoid twisting the polymer
suspension insulators when
attaching insulators and
hardware to structures
Proper checking of verticality of the
structure to be done at every stage of
erection.

Do not exceed the loading and
strength of the ERS structure,
as calculated by ERS
Computer Programs.
Maintain a positive hold on all guy
wire rigging at all times, because the
loss of one guy can cause the
structure to collapse
Never over tighten the
intermediate guys
Only essential personal should be
near the structure during erection
ERS structures shall not be
located so that same are under
up-lift condition.
Use chain hoists or a come-along
when adjusting the guys or side
guying a column during erection. Do
not use turn-buckle for adjusting the
guys.
Do not allow bending of
polymer insulators during
pulling of conductors
The ERS structure is designed for
compressive loads, not bending
loads. All loads should be guyed at
the same height as the load.
Do not use preformed armour
grips after they are used 2-3
times.
ERS bolts should be torqued to 95 to
120 Newton-meters. Lock washers
should always be used
Cross plate anchors shall not
be used in loose soil
Whenever possible, install 7 foot and Bolt less than diameter shall
14 foot column sections below any
21 foot sections.
not be used for connecting guy
plate with the guy wire
Only rotate the Gimbal to the ground
in one of the four directions indicated
by the arrows on the Gimbal

Remove the turnbuckles from the
Gimbal prior to assembly and
erection of ERS structure, or after
permanent guys are attached. Do not
reinstall the turnbuckles after erection
of ERS column structure

Always provide ERS towers at safer
place away from the soil erosion
area.

Safe working space for permanent
measures to be adopted around the
existing towers

The location of emergency
restoration structure should
maintain adequate electrical
clearance from the existing ckt. and
from the ground.

Right of way requirement shall be
kept in view for each voltage class.

Adequate no. of erection guys shall
be provided

If metal slings are used, put pieces of
woods between the slings and the
ERS column to avoid damage to
column.


















21.0 TROUBLE SHOOTING





21.0 TROUBLE SHOOTING

21.1 SURVEY

Certain T&P such as theodolite, chains, ranging rod etc. are required for
spotting the ERS structure. However, the availability of such T&P at
actual worksite may take few days which delays the restoration of critical
lines for supply of power. In case of lines upto 220kV, it is not difficult to
fix the ERS locations by walking over the entire route. The ERS is
capable of supporting 400kV twin conductors, minor variation in the
loads and angle of deviation for lines upto 220kV will not cross the
capability of the towers.

Even for 400kV by-pass of one or two towers, the survey work can be
done without using T&P, thus saving in the time for restoration work.

21.2 EXCAVATION OF PITS AND ANCHORING

In case of unapproachable areas and also to expedite the excavation,
light duty excavator which may be available in the nearby areas can be
used.

It may be possible that even after completion of anchoring work,
anchoring may start coming out at the time of stringing. In such situation
additional boulders/dead weight should be compacted in the pit
excavated areas. Alternatively, additional pits may be made to share the
load of the conductors.

21.3 TOWER ERECTION

In case of loose soil, the foundation plate may not get sufficient
compression area. In such a situation, four anchors can be buried in the
ground on which the foundation plate can be placed to stablise the
foundation.

If the towers is to be located in low lying area with the possibility of sub
mergence, one number guy plate can be provided between foundation
plate and Gimbal joints. This Guy plate in all the four directions can be
connected to anchors through guy wires. This arrangement will not allow
tower to slide from its position even after sub mergence by water.

21.4 STRINGING

As polymer insulators due to its light weight are being used to strung the
conductor but during pulling the conductor for stringing there is tendency
to bend long rod polymer insulator. Too much bending of the insulator is
not advisable. In such a situation the hanging end of the polymer
insulator can be guyed on both sides with the help of rope so as to avoid
its bending during pulling of conductors.

21.5 ELECTRICAL CLEARANCE

The work of restoration is normally done under extreme emergency.
There may be oversight in checking the proper clearance at planning
stage. The conductors may not get sufficient electrical clearance from
the guy wires after final stringing. In such a situation insulated guy wires
with the help of polymer insulators can be used near the conductors
which will enable us to charge the line without any problem of electrical
clearance.














ANNEXURE -I

BILL OF ERS MATERIALS IN ONE SET





Annexure -I

BILL OF ERS MATERIALS IN ONE SET

SL
NO
PART NO
DESCRIPTION Size
(mm)
Weight
(kg.)
Emergency Restoration Structure Components
1. 7154 Foundation Plate (Base) 1524x1524
x356
250
2. 7424 Rigid Gimbal Joint Assembly (7ft.)
(2.13 meter)
889 x 889 252
3. 7153 7 Ft Column (Tower Section)
(2.13 meter)
889 x 889 123
4. 7152 14 Ft Column (Tower Section)
(4.26 meter)
889 x 889 189
5. 7151 21 Ft Column (Tower Section)
(6.4 meter)
889 x 889 256
6. 7157 45- 45 Guy Plate (Anchor Plate) 889 x 1219 x
13
23
7. 7156 0- 45 Guy Plate (Anchor Plate) 889 x 1219 x
13
23
8. 7158 0- 0 Guy Plate (Anchor Plate) 889 x 1219 x
13
23
9. 7155 Box Section 889 x 889 x
457
123
Conductor and Guying Hardware
10. 3262BNC 60 KIP Anchor Shackle (267 KN) D=63.5 1.2
11. 3405 60 KIP Chain Link (267 KN) 0.7
12. R-
11271/120
Strap (Chain Link)
13. R-10929 30 KIP Ext. Strap (Link Extension)
(133.5 KN)
2.5
14. R-9058 30 KIP Triangular Yoke Plate with
two holes/clamps (133.5 KN)
7
15. R-9058 30 KIP Triangular Yoke Plate with
three holes/clamps (133.5 KN)
7

SL
NO
PART NO
DESCRIPTION Size
(mm)
Weight
(kg.)

Conductor and Guying Hardware contd.
16. 7610 60 KIP Universal Yoke Plate with two
holes/clamps (267 KN)
12.2
17. 7610 60 KIP Universal Yoke Plate with
three holes/clamps (267 KN)
12.2
18. 3790EE 7/8 x 12 Turnbuckle EYE-EYE 3.7
19. R-10850 End Cap Adaptor
(Insulator Blade Adaptor)
4.5
20. 1701SY Strain Clamp 3.2
21. 1703SY OHGW Strain Clamp (earthwire) 5.89
22. 1708SY Quadrant Strain Clamp (conductor)
(Strain Deadend Clamp)
5.89
23. 1329 18 KIP OHGW Suspension
Clamp(earthwire) (80 KN)
1
24. 1415/111S
Y
15 KIP EHV Suspension Clamp
(conductor) (67 KN)
3.17
25. 7640/475 5/8 Swaged Socket Cable D=15.8,
L=14300
17
26. 7640/215 5/8 Swaged Socket Cable D=15.8, L=6400 9
27. 3-324 5/8-11 HEX Std. Zinc Nut
28. 7500-3 5/8-11 x 3 ERS Zinc Bolt
29. 3-206 5/8 Galvanised Lockwasher
30. R-14373 25KIP RTL Suspension Polymer
Insulator (SML-50 000 lb, 111 KN)
Specified Mechanical Load 22.25
KN
D=101, L=2380 10
31. R-14373-1 Hot End Corona Ring for
Suspension Insulator with 0.38-16
UNC U bolts nuts and Lockwasher
D=305 2.3


SL
NO
PART NO
DESCRIPTION Size
(mm)
Weight
(kg.)

Polymer Insulators

32. R-14373-2 Cold End Corona Ring for
Suspension Insulator
2.3
33. R-14374 Station Post Insulator/ Line Post
Insulator
D=193, L=1971 27
34. R-14374-1 Hot End Corona Ring for Station
Post Insulator with
(i) 3/8-16 UNC U bolts nuts and
Lockwasher steel HDG
(ii) 1/2-13 UNC Hex head cap scr.
Steel HDG
D=305 2.3
Guy and Anchor Assemblies
35. R-13531 9/16 EHS Guy Wire
36. R-14375 Guy Assembly consisting of
7950 (i) 1 each Wire Rope Thimble
(Guy Wire Thimble)
0.34
R-13467 (ii) 2 each Big Grip Deadend
(Prefromed Guy Grip)
2.3
37. R-13193 Cross Plate Anchor Assembly
consisting of

R-13193-1 (i) 1 each - Tripleye Anchor Rod
(Guy Adaptor)

R-13193-2 (ii) 1 each - Cross Plate Anchor
38. R-14384 Marsh Anchor Assembly
R-14384-1 (i) 1each - Tripleye Guy Adaptor
R-14384-2 (ii) 1 each - Triple Helix Lead
Section

R-14384-3 (iii) 2 each - 10 Foot Extension
R-14384-4 (iv) Fork Installation Tool (Marsh
Anchors Installation Tool)

R-14384-5 (v) Fork Installation Tool Body
227 (vi) 1 each -10x 4 Hex Head
cap Bolt

232 (vii) 3 each -10 Hex Standard
Nut


SL
NO
PART NO
DESCRIPTION Size
(mm)
Weight
(kg.)
Guy and Anchor Assemblies contd.

39. R-13215 Rock Bolt Anchor Assembly
R-13215-1 (i) Rock Bolt Anchor Assembly Part
R-13215-2 (ii) S1 Key hole bearing steel plate
Washer

R-13215-3 (iii) E1 eye bolts
40. R-13216 Rock Bolt Anchor Accessories
R-13216-1 (i) Cement Grout
R-13216-2 (ii) KWIK-SET (A), Sealant
R-13216-3 (iii) Rock bolt set Tool
R-13216-4 (iv) Long fitting tool adopter
R-13216-5 (v) Grout tube adopter
Tool and Plants
41. R-14677 Gin Pole (Derrick) accessories
consisting of
L = 7.3 meter 113.4
3262BNC (i) 2 each 60 KIP Anchor Shackle
R-14677-1 (ii) 1 each 24 Ft. Main Column of
Gin Pole

R-14677-2 (iii) 1 each - Bottom Attachment
Assembly.

R-14677-3 (iv) 1 each - Top Attachment
Assembly.

R-14677-4 (v) 1 each - Winch Line Roller
Assembly.

R-14677-5 (vi) 1 each - Gin Pole Attachment
526 (vii) 1 each 1/2-13 NC x 1 Hex
Head Cap bolt

42. R-14299 6 Ton Chain Hoist
43. R-14188 Grout Hand Pump
44. R-14189 30 Ton Center Hole Test Jack
(Hydraulic Jack)



SL
NO
PART NO
DESCRIPTION Size
(mm)
Weight
(kg.)
Tool and Plants contd..
45. R-14190 Torque Wrench with Ratchet.
46. Expanding and Tampering Bar 254 meter 10
47. R-14300 Pulling Eye with 2.26
(i) 5/8 NC x 2 5/8 Lg Cadmium
Plated Bolt and Nut

E-958 (ii) Adopter Bushing
48. R-14301 Automatic Guy Wire Grip
49. R-14302 10 Foot Metal Sling (3.04 meter)
50. R-14303 10 Foot Nylon Sling (3.04 meter)
51. R-14305 10 KIP Conductor Lifting Hook with
R-14305-1 (i) Hook body Sub-Assembly
902-20 (ii) Key Ring
52. R-14296 15 Reversible Ratchet
53. R-14297 Sq. Drive Deep Socket
54. R-14298 15/16 12 Point Structure Box
Wrench

55. 7001 ERS Computer Analysis
Programmes

56. R-14385 20 Ft. ERS Container
57. 7000 50 : 1 ERS Scale Model
58. Aluminium Rollers
59. Hydraulic Anchors
60. Motorised Gin Pole
61. R-15107 3 Ton Chain Hoist
62. R-15258 6 Ton Hydraulic Wire Cutter



SL
NO
PART NO
DESCRIPTION Size
(mm)
Weight
(kg.)
Tool and Plants contd..
63. R-16732 6 Foot Steel Cable Sling
64. R-14305 Metal Stake , 1.5 M 1 D
65. R-15037 12 lb Sledge Hammer
66. R-16780 Snatch Block
67. 7002 ERS on site training
68. R-16779 Field Engineer Construction Survey
kit

69. R-14385B Specially outfitted 20 foot storage
container to hold hardware,
insulators, guy plates, guy and
anchor accessories and nut and
bolts.















ANNEXURE -II
LIST OF ADDITIONAL TOOLS & PLANTS

Annexure -II
LIST OF ADDITIONAL TOOLS & PLANTS

Sl
No.
DESCRIPTION UNIT Qty.
1.
Four sheave pulley with wire rope block
Set
2
2. Single sheave pulley (open and snatch type)
2.5 TON
5 TON

No.
No.

5
5
3. Equality pulley No. 1
4. Compression machine with die set Set 1
5. Moose and Zebra conductor dies
Aluminium
Steel

Set
Set

1
1
6. Sagging winch machine No. 1
7. D-Shackles (10 ton capacity) No. 10
8. Turn buckles (10 ton capacity) No. 10
9. Conductor drum lifting jacks No. 2
10 Poly propylene rope.
20 mm
16 mm
12 mm

Length (meter)
Length (meter)
Length (meter)

200
400
300
11. 12 mm dia steel rope Length (meter) 150
12. Slings
(i) 20 mm, 50 MTR
(ii) 16 mm, 10 MTR .
(iii) 16/19 mm, 3 MTR .
(iv) 12 mm, 1.5 MTR

Nos.
Nos.
Nos.
Nos.

4
4
10
10
13. Crow bars/spikes (22 mm., 1.5 MTR) No. 50
14. Hammers No. 2
15. Tool box No. 2
16. Safety belts No. 10
17. Safety helmets No. 20
18. Bolted come along clamp for Moose/ Zebra No. 20

Sl
No.
DESCRIPTION UNIT Qty.
19. Automatic Bolted come along clamp for
Moose/Zebra
No. 10
20. Bolted come along clamp for Earthwire No. 4
21. Aerial rollers for zebra/Moose No. 20
22. T-connector No. 20
23. A.P.G. clamps No. 10
24. Tractor for Trifor No. 1
25. Torque wrenches of various size Set 1
26. Conductor Jointing Equipment No. 1
27. Theodalite and chains No. 1
28. Dumpy Level No. 1
29. Crane with capacity and boom length of 6.5 ft. No. 1
30. Tractors No. 2
31. Spades No. 10
32. Shavels No. 10
33. Rammers No. 2
34. Aluminium Ladder of 6 mts. Length No. 1
35. Ground Rollers No. 20
36. Conductor Mid-span socks No. 2
37. Conductor end socks No. 2
38. Wooden Ballies (3 mts.X 2 to 3 dia) No. 10
39. Earthing Rods No. 4
40. Wooden sleepers No. 20
41. First Aid Box No. 1

















Annexure III

DETAILED GUIDELINES FOR
TRANSPORTATION OF ERS STRUCTURE IN
TRUCK OF 18 FEET LONG BODY


Annexure III

DETAILED GUIDELINES FOR TRANSPORTATION
OF ERS STRUCTURE IN TRUCK OF 18 FEET LONG
BODY

One aspect of the ERS that should not be overlooked is the transporting
of equipment and manpower from storage yards to the construction site.
The type and availability of transportation equipment vary in different parts
of country. So the proper transportation procedure is a site-specific
solution.

In our country, the availability of certain type of truck transports may be
limited. Because of this limitation, the transportation of ERS columns may
become of bottleneck during an emergency condition. However, this
problem can be solved with inventive solutions and pre-planning.

One of the problem is the fact that the typical transport truck in India is a
flat bed truck with a bed approximately 8 feet wide and 16 feet long to 18
feet long. However, in remote locations where the ERS structures are
typically stored the availability of 40 foot trailers is limited. During an
emergency, time is of the essence and in most cases contracting with
local haulers is much less time consuming than trying to locate larger
trucks.

The typical flat bed truck in India is three sided with a bed 8 feet wide and
16 to 18 feet long. The height of the bed is approximately 5 feet above the
ground. The ERS columns can be loaded onto these trucks using small
cranes, boom trucks or manpower. One of the problems with a truck that
is only 16 to 18 feet long is the 21 foot column sections will hang out the
back and not be supported.

The solution would be to construct wooden cradles that would allow the
21 foot column sections to be supported at the back end of the truck bed.
The advantage of the wooden cradles is they are simple to make and are
lightweight. The following is a detailed recommendation on using wooden
cradles to transport 21 foot columns :

Recommendations for Transporting 21 Foot Column Sections on
Short Trucks utilising Wooden Cradles on flat Bed Trucks

When transporting 21 foot ERS column sections on trucks that are shorter
then 21 feet (6.4M) the following procedure to avoid damage to the
column sections may be adopted:

Construct one cradle, which will support the back end of the column
sections on the 3X3 main angles, as shown in Figure 34. The front end
of the column sections can sit on the end flanges.

Use short lengths (300-400 mm) of 2X4 boards to separate the column
sections when stacking, as shown in Figure 35. These boards will protect
the towers plate gussets from damage and wear.

Depending on the size of truck and local regulations on allowable height
and width, up to 9-21 foot column sections can be transported on a small
flat bed truck.

Insure that the entire load is securely tied down with straps or ropes. If
metal slings are used, put pieces of wood between the sling and the ERS
column to avoid damage to the column. Insure that the wooden cradle is
adequately secured to the truck or column sections to avoid having it
vibrate out of position during transport.

Observe all safety precautions normally applied when transporting large
size loads.

Please note that since this truck was loaded only as an example, the load
was not adequately tied down over-the-road transport. It is important to
secure to columns to the truck in such a manner that they will not come
loose when travelling over rough roads.









































Figure-34























Figure-35














ANNEXURE IV

SAMPLE ERS COMPUTER PRINTOUT



Annexure IV


Sample ERS Computer Printout


1. Horizontal Vee
2. Delta Horizontal Vee
3. Deadend
4. Running Angle (Single Phase)
5. Running Angle (Three Phase)
6. Chainette
7. Four Pole
8. Herringbone SC
9. Herringbone DC
10. P Critical Analysis
11. Column Erection Analysis















ANNEXURE V

DEMONSTRATION OF ERECTION OF COMPLETE
ERS TOWER BY HELICOPTER






Annexure - V
DEMONSTRATION OF

ERECTION OF COMPLETE

ERS TOWER

BY HELICOPTER



POWER GRID CORPORATION OF INDIA LTD.
CORPORATE OPERATION SERVICES
HELICOPTER DEMONSTRATION

1.0 As per approval of the management, Helicopter demonstration was arranged
at Dehgam substation near Ahmedabad on 11.11.98. The event was
witnessed by Hon'ble Minister for Energy of Gujarat State, GEB Chairman
and senior officers from POWERGRID. Following works were demonstrated
:-

i. One no. completely assembled ERS tower on ground in horizontal position
was lifted by helicopter in vertical position and the same was carried to site
of erection which was about 500 meter. This completely assembled structure
was erected directly by helicopter in a vertical position (see exhibit-1&2)
without keeping this structure in horizontal position on ground. The total time
taken by helicopter was approximately 35 minutes. The purpose of this
exercise was to lift, transport for short distance and erect completely
assembled ERS tower.

ii. One structure was completely assembled on ground in horizontal position.
This structure was lifted and erected vertically (see exhibit-3&4) at the same
place by helicopter. This had taken 8-10 minutes. The purpose of this
exercise was to erect the assembled tower at actual site of damage.

The first operation involving lifting of ERS tower, transportation over a
distance of 0.5 km. and erection at site took about 30-35 minutes. As this
was first operation, about 15 minutes were lost in the actual positioning the
structure on ground. For positioning the structure at required place, the
bottom of structure has to be tied with four ropes, which was not done in this
operation, so that ground staff can hold the ropes for exact positioning of
structure. Hence, this problem could be resolved by tying the four ropes in
the bottom of structure and thereby reducing the time from 30-35 minutes to
15-20 minutes in the following manner: -

a. Lifting of structure would take maximum 5 minutes.

b. Vertical erection of the structure will take maximum 5-10 minutes.

c. Then, transportation time depending on the short distance of few kms.
may take around 5 minutes.

These timings as at a) & b) above are based on the experiment conducted as
per sl.no. ii above.

2.0 As regards long distance transportation of ERS with helicopter, the same
may not be practical in most of the cases in view of following constraints :-

i. Only 10 sets of ERS are available with us and same are located at very far
distances from each other.

ii. Pawanhans helicopters of required capacity are located only at Mumbai and
Guwahati and their transportation time from these places to actual site of
damage would take a very long time.

iii. Though ERS is a very light weight structure, yet, the structures due to its
size cannot be accommodated inside the helicopter. There has to be an
under carriage of structures which would require extra precautions and
special approvals from the concerned authorities.

iv. Only one structure in assembled position or bundled in pieces and tied
together can be transported at a time. In case of requirement of 5-7
structures, helicopter will be required to make 5-7 trips. This preposition then
becomes very costly.

v. Refueling of helicopter while under carriage of ERS tower is not very much
feasible.

For long distance transportation of ERS, the same can be adopted in case,
the requirement is limited to one or two ERS towers, distance of store to the
damaged site does not require refueling of the helicopter and there is loss of
generation.

As the helicopter of M/s Pawanhans are not available at many places, efforts
are being made to initiate dialogue with Ministry of Defence for utilizing their
helicopters in emergent situations like backing down of generation/ cyclone
affected areas. The helicopters of army/ airforce are available in the remote
areas and at many places, refueling of helicopter from place of helipad to ERS
store/ damaged site may not be required.

3.0 In view of constraints in long distance transportation of ERS and also due to
non-availability of helicopter of M/s Pawanhans at many places, following
actions are being taken separately: -

i. Presently, 10 sets of ERS are available. Maximum 12 towers can be made
from each set. As per experience gained till date, maximum 7 no. of ERS
towers have been used at a time. So, 10 sets of ERS can be divided into 20
sets with each set will have 6 towers. These 20 sets can be re-located in
strategic locations in consultation with regions in such a way that distance
between any two sets is not more than 400-500 Kms. In this
way, transportation time of ERS can be reduced not only for helicopter
purpose but also for conventional road transportation. The exercise is being
done in consultation with regions.

ii. As helicopters of Army/ Air Force are located at many places and in remote
areas, it is proposed to initiate discussions for using their helicopters in urgent
situations.

4.0 It may be concluded that actual time taken by helicopter for erection of ERS
structure at the place of damage or for transportation of short distance i.e.
from the main road site to the actual damage site could be limited to
maximum 30-35 minutes in each operation. With this technique, erection of
ERS for an average damage of towers 5-7 nos. can be carried out easily in
half-day time. This will only require sufficient no. of slings and pull lifts for
lifting and guying of structures. The cost of these items is very minimal as
compared to the per hour hiring rate of the helicopter. However, the
conventional time is around one day per tower erection per gang and total
time would be 5-7 days for 5-7 no. of erection of structures. Hence, there will
be saving of 4-6 days in erection of ERS towers only.
Exihibit-1









ERS COLUMN ASSEMBLY IN READY POSITION

FOR LIFTING BY HELICOPTER

Exihibit-2



HELICOPTER ERECTING E R S COLUMN

AFTER FLY IN FROM STORE
Exihibit-3





HELICOPTER TILTING UP ERS COLUMN

Exihibit-4

HELICOPTER TILTING UP ERS

COLUMN (IN PROGRESS)



















ANNEXURE VI

IMPORTANT EXAMPLES OF USE OF ERS AT
CRITICAL LOCATIONS (220 KV D/C BAIRASUL-
PONG LINE AT TOWER LOCATION NO. 59)















Annexure VI
CONSTRUCTION OF

ERS BYPASS

OF

THE BAIRASULPONG 220 kV TOWER NO. 59
RAVI RIVER CROSSING

BY

POWERGRID CORPORATION OF INDIA, LIMITED
Northern Region - II




September 1996


Summery of Events

A massive of earth slide in June of 1996 triggered by the saturation of soil due to spill
way discharge resulted in the destabilization of tower number 59 on the Bairasul-
Pong 220 kV D/C transmission line which is located just above the slide area (see
photograph 1 & 2).

Since the catastrophic slide occurred, the tower location is being checked weekly.
The results were that the ground is slowly moving. The Power Grid Corporation of
India Limited (PGCIL) decided to utilize its Emergency Restoration (ERS) to increase
the reliability of the transmission line. Figure 1 is a sketched profile of the damaged
and failing tower number 59 and the towers to either side of it.

Restoration Plan

After review the damaged tower the Powergrid decided the best approach was to
reduce the load on the damaged tower. This would be accomplished by removing
the outside circuit on the 12 degree angle strain tower and moving it to a by pass
ERS tower located above tower 59 (see figure 2). Because ERS had just supplied to
the Powergrids Northern Region II it was decided to combine the training session
with the actual restoration.

The Powergrid contacted supplier and a Field Engineer was dispatched to India for
the purpose of conducting the training session. The training session took place in
September of 1996.

Mobilization and Staging

Prior to the arrival of suppliers Field Engineer on September 9, Power Grid
Engineers developed bills of material for the proposed bypass towers and began to
move the equipment from storage areas to the tower site. The closest road and
staging area was approximately 2.5 kilometer from the tower site. All of the
equipment had to be hand carried from the staging area (see photograph 3 & 4).

Site Conditions

The site condition were very difficult. The original tower was constructed on steep
sloped terrain. The average slope of the terrain towards the river was 40 degrees.

The first step was to determine the type of towers to be used in the bypassed
scheme. After reviewing the site and analyzing the ERS on the computer programs,
the Powergrid and suppliers Engineer agreed that two, three phase tension
structures would work best for the given site condition. The Engineers located the
two foundation sites and the related anchor positions. Digging holes for the anchors
commenced immediately. The criteria for locating the towers was to maintain
electrical clearance from the existing circuit and from the ground.

Construction of the ERS

Once the anchor plates were buried the actual construction of the towers began.
Foundations were located and staked down. The Gimbal was bolted to the
foundations and the Gin Pole (derrick) was moved into place (see photographs 5 &
6). Each tower was completed in approximately 1 day. Once both towers were
completed, new conductors were strung between the ERS towers. An eight hour
outage was then taken to transfer the conductor from tower 59 to the ERS 12 degree
strain tower. This was accomplished by using a block and tackle to lower the
conductors from tower 59 to the ground and then pulling the conductors into position
on the ERS towers (see photographs 7 & 8).

Energizing Bypass ERS Line

On September 20 the transmission line was energized (see photographs 9 & 10).

The training session construction of the bypass line took less than 2 weeks.
Approximately 30 people were utilized in the bypass construction. It is estimated that
the construction time could be reduced by 30% now that linemen have been trained
in the use of the ERS.

Future Plans

With the bypass line energized the Powergrid now has time to evaluate foundation
locations for a new tower to replace tower 59.

Conclusion

The Powergrid was able to increase the reliability of the BairasulPong 220 kV
double circuit line by utilizing the Lindsey ERS structures to by-pass the failing tower.
The linemen and engineers gained valuable experience in the implementation of the
ERS in a critical situation and difficult site.



























23.0 REFERENCES
23.0 REFERENCES


Following References of M/s Lindsey Manufacturing Company, USA have been used
in preparation of this document:-

1. Catalogue on Emergency Restoration System

2. Computer Program for analyzing structures
(Revised November 1, 1990)

3. Instruction Manual (January 1997) for Lindsey Modular Emergency
Restoration structures

4. A document on Transporting Emergency Restoration System Structures
(July 1996)